Section 5 — Piping

IPE-EP-5-4-1

IPE Engineering Practice IPE-EP-5-4-1

Document number: IPE-EP-5-4-1 · Section: 5 — Piping

CoInafsletcatilo nA Prouinbta E nEgningeeirninege Prriancgtic Pesractices Metal Expansion Joints 4) Bellows design calculations in accordance with EJMA and/or the applicable design code and the requirements of this Practice. The design calculation shall include expansion joint spring rates and bellows metal temperature calculations where required in the design. For rectangular bellows, the justification of the stress concentration factors required in the EJMA performance equations. 5) Test procedures including test pressure. 6) Welding procedures in accordance with EP 5–5–2. 7) For two–ply bellows, details of the leak detection device. 5.2 (*)The following information shall be supplied to the Owner’s Engineer for approval prior to start of fabrication. 5.2.1 Fabrication procedures including as a minimum: 1) Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) 2) Weld repair 3) Cleaning 4) Preparation for shipment 5) Non–destructive examination 6) Pressure tests 7) Heat treatment 5.2.2 Certified Material Test Reports 5.2.3 Fabrication drawings for all details showing: 1) Owner job and requisition numbers 2) Equipment mark number/identification 3) All assembly dimensions and clearances 4) All materials of construction 5) All welding details and materials 6) Size and location of all connections 7) Instructions for the unit installation and removal of all temporary positioning devices 8) Design conditions and any special installation requirements 9) Direction of flow through the joint 10) Test pressure 11) Complete bellows description including: thickness, inside and outside diameter, pitch and number of convolutions, number of plies, as well as corner type and convolution profile for rectangular bellows. All dimensions required in the expansion joint stress equations in EJMA shall be shown. 12) Assembly weight 13) Flange size and facing; non–standard flanges shall be fully dimensioned. 14) For two–ply bellows, details of the leak sealing device. 15) Shipping restraint details. 5.2.4 Shipping restraint calculations 5.3 Final requirements are stipulated for final documentation in Table 1.

CoInafsletcatilo nA Prouinbta E nEgningeeirninege Prriancgtic Pesractices Metal Expansion Joints 8.4 (*)For rectangular metal bellows expansion joints where the process temperature exceeds 800°F, internal refractory lining or an internal liner with or without an annulus packed with ceramic fiber insulation shall be used to maintain the bellows metal temperature between 400°F and 800°F. The Owner’s Engineer shall specify the use of refractory lining, an internal liner, and ceramic fiber insulation on the expansion joint data sheet. The Manufacturer shall notify the Owner’s Engineer if measures beyond those specified are required to maintain the metal temperature below 800°F. All calculations/justification for the metal temperature determination shall be submitted to the Owner’s Engineer for review and approval. 8.5 Unless otherwise specified on the Expansion Joint Data Sheet, all circular metallic bellows elements shall be 2 ply construction formed from two concentric tubes having only longitudinal seams with a non–galling, metallic mesh between the plies. Each ply shall be capable of retaining the design pressure at temperature independently. The minimum thickness of each ply shall be 0.03 inches. 8.6 When two ply bellows construction is used, the bellows ply space shall be provided with a passive pressure monitoring device which will give operators an indication of a leak in the primary bellows. The leak device shall be capable of being tested by applying a pressure at the location of the monitoring device and 180 degrees offset. If a vacuum between the plies is required by the device, a means to re–establish the vacuum during operation shall be provided. The test devices illustrated in Figures 2, 3, and 4 are not intended to prevent the Manufacturer from using other devices that satisfy these requirements. 8.7 (*)Proposals to use reinforcing rings when not specified on the Expansion Joint Data Sheet shall be submitted to the Purchaser for approval by Owner’s Engineer. 8.8 Convolution profiles shall be as follows: 1) U–shaped for circular bellows, formed with an even pitch and matching height. 2) V–shaped or U–shaped for rectangular bellows. The convolution height shall be equal to a minimum of twice the pitch, with matching root and crest radii and convolution height. 8.9 (*)When a packed bellows is specified on the Data Sheets, the bellows/internal liner annulus shall be packed with ceramic fiber insulation, see Figures 1C, 1H, 2C, 2H, 3C, or 3H. The fiber insulation shall be mechanically sealed by a stainless steel braided hose or other acceptable method. The braided hose shall be woven to a consistency that assures elastic operation for the number of specified cycles and shall be sufficiently elastic to be in a compressed state under all operating deflection conditions. The hose shall be installed as one piece and continuous. The bulk insulation in the annulus shall be the blanket type, if possible, and shall be encased in a tightly woven stainless steel wire mesh bag. The thickness of the insulation shall be designed to maintain the bellows metal temperature above the dew point of the process fluid. If external insulation is required to maintain the bellows above the dew point of the process fluid, the manufacturer shall supply the expansion joint with the insulation; the insulation shall be a removable blanket type so that the bellows can be inspected. 8.10 (*)Where a refractory lining is specified on the Expansion Joint Data Sheet, it shall be installed in accordance with EP 11–1–1. Lining type and thickness shall be as specified on the Expansion Joint Data Sheet.

CoInafsletcatilo nA Prouinbta E nEgningeeirninege Prriancgtic Pesractices Metal Expansion Joints 4) (*)Specify round or rectangular expansion joint. 5) (*)The data sheet provides for a design condition and two additional operating conditions. The design condition is the design condition for the system. Two additional operating conditions such as regeneration or afterburning can be specified on the data sheet. Use additional data sheets if more operating conditions must be specified. 6) (*)Specify the item number and/or tag number. 7) (*)Specify the number of the line in which the expansion joint is being placed. 8) (*)Specify the quantity of this expansion joint to be supplied. 9) (*)For round expansion joints specify the nominal pipe size or pipe or duct O.D. or I.D., as appropriate, and thickness. For rectangular expansion joints, specify the duct outside dimensions (height and width) and thickness. 10) (*)Specify the expansion joint type (single, universal, pressure balanced, unrestrained, hinged, gimbal, tied, etc., as appropriate) and,for circular metal bellows, Type (see Paragraph 8.2). 11) (*)Specify the process fluid including its state (gas/liquid). 12) (*)Specify the flow velocity. 13) (*)Specify the flow direction. 14) (*)Specify the fluid density. 15) (*)Specify the dew point above which the bellows metal temperature must be maintained, if applicable, to prevent acid condensation and corrosion. 16) (*)Specify the design pressure for the design condition and the pressure for additional operating conditions. 17) (*)The test pressure shall be in accordance with Paragraph 13.1 and 13.2. The manufacturer shall determine the required test pressure in accordance with these rules. Only specify a test pressure if a higher test pressure is required by the system design. 18) (*)Specify the temperature of the process fluid. 19) (*)Specify the maximum permissible and minimum permissible bellows metal temperature for the stated process temperature. See Paragraph 8.3 for circular expansion joints and Paragraph 8.4 for rectangular expansion joints at high temperatures. 20) (*)Specify the ambient maximum and minimum temperatures, specifically considering the expansion joint location. 21) (*)Specify the duration of each condition. The total of the hours for the specific conditions should at least be equal to the required design life of the expansion joint. 22) (*)Specify the required axial compression capability, in addition to design movements, to accommodate piping or duct misalignment on installation. See Paragraph 9.3. 23) (*)Specify the required axial extension capability, in addition to design movements, to accommodate piping or duct misalignment on installation. See Paragraph 9.3. 24) (*)Specify the required lateral displacement capability, in addition to design movements, to accommodate piping or duct misalignment on installation. See Paragraph 9.3. Lateral displacements shall be specified in one or two directions, depending on the joint configuration. 25) (*)Specify the required angular displacement capability, in addition to design movements, to accommodate piping or duct misalignment on installation. Rotation shall be considered to be about any axis normal to the pipe centerline unless the joint is hinged or the direction of angular rotation is shown in the isometric sketch. See Paragraph 9.3. 26) (*)Specify the design axial compression of the expansion joint for the condition. See Paragraphs 9.3 and 9.5. 27) (*)Specify the design axial extension of the expansion joint for the condition. See Paragraphs 9.3 and 9.5.

CoInafsletcatilo nA Prouinbta E nEgningeeirninege Prriancgtic Pesractices Metal Expansion Joints 28) (*)Specify lateral displacement (normal to the pipe centerline) of the expansion joint for the condition in one or two directions, depending on the joint configuration. See Paragraph 9.3 and 9.5. 29) (*)Specify the design resultant angular displacement of the expansion joint for the condition. See Paragraphs 9.3 and 9.5. Show the direction of the resultant on the isometric sketch on the data sheets. 30) (*)Specify the number of cycles for the displacement condition. 31) (*)Specify the axial compression due to operating fluctuations that is superimposed on design movements. See also requirements for line 23. 32) (*)Specify the axial extension due to operating fluctuations that is superimposed on design movements. See also requirements for line 24. 33) (*)Specify the lateral displacement due to operating fluctuations that is superimposed on design movements in one or two directions, depending on the joint configuration. See also requirements for line 25. 34) (*)Specify the angular rotation due to operating fluctuations that is superimposed on design movements. See also requirements for line 26. 35) (*)Specify the number of cycles for the displacement condition due to operating fluctuations. 36) (*)Bellows material of construction. See Paragraphs 7.1 and 7.2. 37) (*)Specify the liner material of construction. Note “if required” if the liner is at the manufacturer’s option based on the manufacturer’s criteria. 38) (*)Specify the cover material if an expansion joint cover is required. See Paragraph 10.4. 39) (*)Specify pipe or duct material per EP 5–2–1. Also specify the schedule or thickness of the mating pipe or duct. 40) (*)Specify the flange if the expansion joint is flanged using standard flanges, see EP 5–2–2. Specify the standard for flange geometry per EP 5–2–2 and ASTM specification for the material. 41) (*)Specify tie rods if required. State their purpose (e.g. tied to prevent axial extension, limit to limit axial extension to a specified amount, etc.) and material of construction. 42) (*)Specify if a pantographic linkage is to be used to equalize bellows displacements and the material of construction. 43) (*)Specify if an anchor base is to be provided on the spool between a pair of bellows. Provide a description of the base if required. 44) (*)Specify if a hinge or gimbal joint is to be provided and the material of construction. State yes or no for lubricated hinges. See Paragraph 10.1. 45) (*)Specify the type of refractory to be used if the expansion joint is to be refractory lined. See Paragraph 8.10. 46) (*)Specify the required thickness of refractory, if required. 47) (*)Specify the upstream end of the expansion joint (e.g. flanged or butt weld). 48) (*)Specify the downstream end of the expansion joint (e.g. flanged or butt weld). 49) (*)Specify the pressure class of the expansion joint if flanges are used. Specify whether of not the pressure class is for cold wall refractory lined flanges. 50) (*)Specify the maximum or required overall length of the expansion joint, if applicable. 51) (*)Specify the maximum outer diameter (or outside dimensions for a rectangular expansion joint) of the expansion joint including hardware and cover, if this dimension must be limited. 52) (*)Specify the minimum or required inside diameter of the expansion joint, including flow liner and refractory, if this dimension must be limited. 53) (*)Specify the maximum axial spring rate of the expansion joint, if required. 54) (*)Specify the maximum lateral spring rate of the expansion joint, if required. For rectangular joints, specify the maximum lateral spring rates in two directions, if required.

CoInafsletcatilo nA Prouinbta E nEgningeeirninege Prriancgtic Pesractices Metal Expansion Joints 55) (*)Specify the maximum angular spring rate of the expansion joint, if required. 56) (*)Specify the installed orientation of the expansion joint. 57) (*)Specify whether or not the expansion joint is to be ring reinforced. Check “if required” if it is at the manufacturer’s option. See Paragraph 8.7. 58) (*)Specify whether or not the bellows are to be two ply testable bellows. See Paragraph 8.5. 59) (*)Specify whether or not the bellows/internal–liner annulus is to be packed with ceramic fiber insulation. Check “if required” if the manufacturer is to determine the need based on heat transfer calculations and the specified bellows metal temperature (range). See Paragraph 8.9. 60) (*)Specify whether or not the bellows is to be externally insulated. Check “if required” if the manufacturer is to determine the need for external insulation based on maintaining the bellows metal temperature above the dew point of the process fluid. See Paragraph 8.9. 61) (*)Specify thickness and type of external insulation if it is specified in line 57. 62) (*)Specify if the requirements for the FCCU expansion joints in Section 16.0 apply. 63) (*)Specify the required axial displacement preset of the expansion joint (use + for extension, - for compression). 64) (*)Specify the required resultant lateral displacement preset of the expansion joint. Displacement shall be specified in one or two directions, depending on the joint configuration. 65) Specify the required resultant bending rotational preset of the expansion joint. Show the direction of the resultant rotation on the isometric sketch unless the expansion joint can only rotate in one direction (i.e. hinged). 66) (*)This entry is optional. Specify the maximum calculated external axial forces acting on the expansion joint when the force is carried by the expansion joint hardware (e.g. tensile force on a tied expansion joint). The calculations may include the effects of pressure thrust based on assumed bellows effective areas. However, the pressure thrust load of this expansion joint should not be included in the axial force. The specified force is to be considered by the Manufacturer to be in addition to pressure thrust in designing the expansion joint hardware. 67) (*)This entry is optional. Specify the maximum calculated external lateral force on the expansion joint when this force is carried by the expansion joint hardware. If specified, the lateral forces shall be specified in one or two directions, depending on the joint configuration. 68) (*)This entry is optional. Specify the maximum calculated external bending moment on the expansion joint when this moment is carried by the expansion joint hardware. 69) (*)This entry is optional. Specify the maximum calculated torsional moment on the expansion joint. 70) (*)Specify the frequency of known significant sources of vibration that the manufacturer must design the bellows to avoid resonance with. If the vibration is causing a cyclic deflection of the expansion joint, specify the type and amplitude of deflection. 71) (*)Specify the applicable Code (e.g. B31.3, B31.1, ASME Section VII I–Stamped, ASME Section VIII– Not Stamped, None). 72) Bellows seam weld NDE. See Paragraphs 12.3 and 12.5. 73) Bellows attachment weld NDE. See Paragraphs 12.3,12.5 and 12.8. 74) Corner and field weld NDE for rectangular bellows. See Paragraphs 12.3 and 12.7. 75) NDE of other welds essential for pressure containment. See Paragraphs 12.3 and 12.7. 76) (*)Specify if a bellows surface liquid penetrant examination is required after forming. See Paragraph 12.3 and 12.6. 77) (*)Specify if a movement test is required. See Paragraph 12.4.

CoInafsletcatilo nA Prouinbta E nEgningeeirninege Prriancgtic Pesractices Metal Expansion Joints 78) (*)Specify any required inspection of the line pipe other than minimum requirements of the specified Code. See Paragraph 12.3. 79) (*)Specify any required painting requirement information. See Paragraph 15.2. 80) (*)Specify any specific packaging requirements (e.g. vendor standard, export packaging, skid, box), see EP 5–4–3. 81) (*)Specify type and location of purge connections, if required. 82) (*)Specify type and location of instrumentation connections, if required. 83) (*)Specify the flange facing, if a special flange design is required. 84) (*)Specify the flange outer diameter, if a special flange design is required (Outer dimensions for a rectangular expansion joint). 85) (*)Specify the flange inner diameter, if a special flange design is required (Internal dimensions for a rectangular expansion joint). 86) (*)Specify the flange thickness, if a special flange design is required. 87) (*)Specify the diameter of the bolt circle, if a special flange design is required (Provide a drawing for a rectangular flange and note “see drawing”). 88) (*)Specify the number of bolt holes, if a special flange design is required. 89) (*)Specify the size of the bolt holes, if a special flange design is required. 90) (*)Specify the hole orientation, if a special flange design is required. If they are not equally spaced, provide a separate drawing with the bolt hole layout and note “see drawing”. 91) (*)If additional requirements not covered by the data sheet such as; special heat treatment requirements, special pipe end components such as reducers, or other fabrication items, they should be included in the Notes section of the data sheet or shown on the isometric sketch accompanying the data sheet.

© 2026 Inflection Point Engineering, LLC. All rights reserved.