Expansion Joint
Systems
O
ur name says it all. Expansion Joint Systems (EJS) designs, markets, and manufactures expansion joints and piping solutions. EJS pro-duces every style of metal and fabric joint. We are the expansion joint professionals.For two decades the name Expansion Joint Systems has meant quality, state of the art tech-nology and worldwide service. Today, we contin-ue to offer consistent customer valcontin-ue, building on the foundation that has made us one of the industry leaders. The EJS team is dedicated to providing our customers with high quality prod-ucts at competitive prices.
EJS is a member of EJMA (Expansion Joint Manufacturers Association) with representatives serving on both the technical & management committees. We hold a current ASME Boiler and Pressure Vessel Section VIII, Division 1 certificate. EJS is also an UOP approved manufacturer.
Customer
Commitment
Our commitment to quality starts at the quo-tation stage. Utilizing state of the art computers and software, including Finite Element Analysis & Parametric Technology, we can help you speci-fy and layout the correct joint for any given application. All expansion joints are computer designed using software developed by EJS engi-neers over the past 20 years. We analyze effects on pipe, restraint loading, and develop the most cost effective and thoroughly tested designs in the industry. The EJS team is always testing new methods, analyzing cause and effect, and devel-oping new bellows technology.
The EJS Commitment doesn’t stop with the design and manufacturing of the unit. We are
available 24-hours a day, 7 days a week for any emergencies. Many joints can be replaced or repaired in as little as 24 to 48 hours. Call EJS at anytime to get your plant up and running again, quickly.
Markets
Expansion Joint Systems continues to build alliances with our customers in the power, oil and petrochemical, pulp and paper, industrial & heavy equipment suppliers, and a variety of OEM mar-kets. With installations found in hundreds of plants worldwide, EJS has truly become a world leader in the industry.
Today we supply most types of metal and fab-ric expansion joints, but we have become special-ists in highly engineered units such as:
FCCU (Fluid Catalytic Cracker Units): Lined,
Unlined, hot wall, cold wall, self equalizing and multi-ply monitored bellows.
CCR (Continuous Catalytic Reforming);
These units require detailed analysis due to the light wall, high alloy shell design.
GTX (Gas Turbine Exhaust); High
tempera-ture fabric expansion joints, including Hot to Cold, Cold to Cold and Hot to Hot designs.
Styrene: These expansion joints
incorpo-rate solution annealed 800H bellows to accommodate extremely high tempera-tures without refractory lining.
LNG: Cryogenic designed expansion joints
Expansion Joint
Systems
O
ur design and engineering team uses the most innovative technology and design software available today. All EJS production drawings are produced using Parametric Technology that pro-vides a 3-dimensional model of the expansion joint. We can translate our drawings into the most commonly used formats, and transmit all the information electronically to our cus-tomers.EJS also uses Finite Element Analysis (F.E.A.) as a standard part of our design process. We have the abil-ity to provide our customers with F.E.A. of all hardware attachments and shell stress levels. Imposed shell stress is an area where precise analysis
is often overlooked, but is a common area of fail-ure on larger diameter units.
As part of our standard design process we run F.E.A. shell analysis and provide our customers with full color imagery of the stress levels imposed by the joint’s hardware. Piping analysis is also available and is
dis-cussed on page 7. As a technologically pro-gressive company, EJS‘s main production plant utilizes state of the art welding technology with all personnel qualified to ASME stan-dards. The bay shown in this photo has the ability to lift 20-ton units and has a hook clearance of 30 feet. EJS is quali-fied to produce ASME section VIII, Division 1 expansion joints and
vessels. And because we take pride in providing quality products, we incorporate in process and final inspection on every part with various NDT procedures utilized as standard practice. Hydro testing, vacuum testing and x-ray are commonly
used methods at EJS. This type of attention to detail pays great dividends assuring our cus-tomer of a well-designed, completely functional
expansion joint, with no surprises in service. EJS also supports projects worldwide through our EJS global offices and manufacturing facili-ties. In addition to our main manufacturing facil-ity in the United States, we also have manufac-turing capability in Canada, Malaysia, Romania and Venezuela. More details about our EJS glob-al can be found on page 9.
Customer Seminars
The EJS team has produced various presenta-tions and lunch & learn seminars on applicapresenta-tions, in-depth engineering and special product discus-sions. We would be pleased to visit your facility to present an educational training seminar for your engineers, planners and purchasing person-nel. Our company also offers customized soft-ware that you can use to help develop your designs and piping layouts.
3D model of a 26-3/8" (67cm) diameter universal round to rec-tangular expansion joint with 2 ply testable indicators for a major refinery.
Expansion joint after final inspection.
W
hether you need hundreds of 6” (15cm) diameter penetration seals for your boilers or a 104” (2.5m) flue gas expansion joint for your refinery, EJS can supply simple to the most com-plex expansion joints. We manufacture both metal and fabric expansion joints from 2" (5cm) nominal diameter to 240” (7m), process temper-atures from -3250F (-198C) to 2,5000F (1371C)and pressures from full vacuum to 2000 psig. (140 kg/cm2) bellows of single-ply, multi-ply,
root ring, equalizer ring and toroid designs are available.
EJS has many sole source agreements for our standard expansion joints, but our expertise is in the highly engineered expansion joints that are typically exposed to extreme conditions such as high temperature, high pressure and large move-ments. These types of expansion joints are gen-erally found in petrochemical and oil refineries, styrene processing plants, C.C.R. and gas turbine
exhaust applications. EJS works directly with engineers and constructors, consultants as well as the end user to design the best expansion joints for their system.
Materials of construction include, but are not limited to such exotic materials as Rene, Hastalloy and all of the often used Inco Alloys. The more common materials, 300 series Stainless Steel and Iconel 625 are stocked by Expansion Joint Systems for emergency deliver-ies.
Fluid Catalytic
Cracking Unit
Expansion Joints
Expansion joints used in FCCU service are some of the most critical and complex types of expan-sion joints manufactured. For this reason, the choice of manufacturer should be carefully con-sidered.
EJS has 20 years of experience designing and manufacturing FCCU expansion joints. These expansion joints are exposed to high tempera-tures (over 1400F/760C), high pressures, large movement conditions, aggressive media. Great attention and expertise is required in designing the bellows and hardware to ensure that the units perform well in service. Failure of FCCU expansion joints during operation can be extremely hazardous to personnel and very expensive to the end user.
Since there are no standard “off the shelf” FCCU joints, all units are designed specifically for each application. Today’s predominant specifica-tion for FCCU joints is the UOP specificaspecifica-tion. EJS is an approved UOP manufacturer and has many years experience building FCCU expansion joints in accordance with the UOP specifcation. Specifications created by other refineries and engineering companies are also supported by EJS.
There are various types of expansion joints used in FCCU applications: Tied Universals, Hinge, Gimbal, and Pressure Balanced. All of these fall into 3 major categories: Cold Wall, Hot Wall, and Unlined FCCU joints. The bellows membrane design for all three categories are similar, although the bellow membrane can be single ply, multi-ply, redundant ply and reinforced. Other accessories and hardware such as monitors, pres-sure retaining covers, control rods, sampling pipes, pantographic linkages, hinges, floating hardware and refractory are commonly installed on FCCU, CCR, and other types of expansion joints for extreme applications. EJS also provides repair, refurbishment, and replacement of exist-ing FCCU expansion joints includexist-ing online clamshell installations with standard and emer-gency deliveries.
Expansion joints for styrene applications must also be designed and manufactured to endure
Hex mesh inside a hot wall FCCU expansion joint
Refractory lined cold wall FCCU expansion joint with pantographs
extreme temperatures. Recently EJS supported one of the largest Polystyrene producers in the world by supplying 24 expansion joint assemblies and piping networks with floating hardware. These units were designed to endure tempera-tures over 1600F (871C) and pressures up to 75 PSIG (5kg/cm2) without refractory lining.
ASME Heat
Exchanger Expansion
Joints
EJS has been designing expansion joints for heat exchanger applications, specifically shell and tube or floating head, for many years. Considered an expert in this application, EJS manufactures all code joints in accordance with ASME Section VIII, Div 1. and all our welders are ASME qualified. Appendix 26 requires a special
code analysis that is provided with these high-pressure expansion joints and a third-party source inspection ensures the expansion joint is manufactured per code. When complete, all parts receive either a "U" or an "R" stamp depending on new construction or repair and a U-2A partial data report.
The convolutions on the bellows may be U shaped or toroidial depending on the design con-ditions. Design pressures range from full vacuum to 2500 psig (175 kg/cm.sq.) with temperatures from -3250F (-198C) to 16500F (899C). As a
minimum, all code joints require 100 percent dye penetrant examination of the bellows longitudi-nal seams and attachment welds along with a hydrotest.
All code joints are manufactured from a variety of SA and SB materials stocked at EJS. These materials require mill test reports and tracking
so each part can be stamped with a unique seri-al number. This seriseri-al number contains a com-plete history of the expansion joints' materials and construction. For more information about toroid expansion joints visit www.ejsus.com and search on "toroid".
EJS is a company dedicated to providing qual-ity products and services backed with a complete guarantee. With one of the most comprehensive quality assurance programs in the industry, our products are inspected and evaluated extensively through each stage of production.
EJS is capable of performing all types of non-destructive testing such as radiography, ultra-sound, mass spectrometer, magnetic particle, hydrostatic and liquid penetrate inspection. We can also include cycle testing, spring rate testing, hardness testing, impact testing, pneumatic test-ing, helium leak detection and positive material
identification (PMI) as part of our program. All inspectors are certified to ASNT-TC-1A with mul-tiple Level II and III inspectors in house.
The design, quality assurance, and manufactur-ing practices at EJS are in compliance with the following codes and standards: EJMA, ASME Section VIII and IX, ANSI B31.1, B31.3 and other major industry standards such as UOP and ISO 9002 (in process).
Installed refractory lined FCCU expansion joint in a flue gas line at a major Texas refinery.
18 ft. (5.4m) long cross over tied expansion joint
High Temperature
Fabrics
E
xpansion Joint Systems is also an established manufacturer of fabric expansion joints. As a leader in high temperature fabric expansion joints, EJS remains closely tied tosome of the world’s top manu-facturers of fabric expansion joints including
ISO 9001 certi-fied manufactur-ers. These rela-tionships enable Expansion Joint Systems to bring quality, innovative
fabric technology to our customers worldwide. The introduction of fabric expansion joints has changed the way engineers solve thermal
growth problems in gas transfer applications. Fabric expansion joints will normally accommo-date large movements over relatively short installation lengths.
Their use in large dusting systems in place of metallic units reduces cost and weight, as well as enables fast, simple replace-ments. EJS designs fabric joints to meet your serv-ice requirements and we offer a range of multi-layer fabrics for low to high t e m p e r a t u r e applications.
Gas Turbine Exhaust
After many years of research, development and testing. EJS has created one of the best GTX
expansion joints on the market today. Our fabric GTX expansion joints offer good performance and longevity. They are available in your choice of frame design and fabric material depending on the severity of the service.
The choice of fabric depends upon flow condi-tions; a standard membrane (GTX-A) heavy-duty membrane (GTX-B) and severe service mem-brane (GTX-C).
Additionally, we have developed a series of frame designs that can accommodate every
application in the gas turbine field.
Basic Frame Types
Hot to Hot - when both of the mating flanges
have to operate at the exhaust gas temperature.
Hot to Cold - when one of the flanges operate
at the exhaust gas temperature and the cold end can have interfaced or standalone type liners.
Cold to Cold - when both flanges are attached
to internally insulated ducting.
All standard designs can be modified to suit any application; however, EJS will not compro-mise our basic design philosophy to accommo-date a requirement that may reduce the life or safety of a unit.
Contact EJS for more information about GTX product lines.
EJS also manufactures standard fabric expan-sion joints including low temp FLEX 250 and fab-ric PenSeal Plus boiler seals.
105" (2.6m) diameter weld end refractory lined fabric expansion joint for a major refinery.
120" (3.5m) diame-ter Hot to Hot GTX Expansion Joint
Standard Expansion
Joints
EJS
offers standard expansion joints in both metal and fabric.PenSeal Plus penetration seals were
devel-oped to address the many problems associated with penetrating the shell of a boiler or similar pressure casing. PenSeals offer a complete seal,
which eliminates the leakage of heat and other emissions, reduces noise and protects mainte-nance personnel. Because they are designed to accept axial, lateral and angular movement these joints lower the stress on the tubes and pipes
they are attached to. PenSeals are available in one or two piece clamshell models and in both metal and fabric material,
Low Temperature
Fabric
Our FLEX-250 is a high quality fabric expansion joint that can withstand temperatures up to 4800F (2500C) with short peak
tem-peratures to 5720F (3000C) for 16
hours accumulated. FLEX -250 is available in both round and rec-tangular designs from 12” (30.48cm) to 160” (406cm) in diameter and to the limit of the truck shipments for rectangular joints. The fabric belt HD-250, used on this series of expansion joints, is a high strength, lightweight flouroplastic material with the ability to resist the chemical attack of sulfur dioxide and most other chemicals.
EJS Online
To improve customer service around the clock, EJS has built an innovative website www.ejsus.com. Our website gives users increased interactivity, search capability, technical information and more importantly, online pricing and ordering for standard and ASME Code expansion joints. The company’s long-term plan is expected to provide 24-hour access to EJS for our cus-tomers worldwide. Our website has been designed to help engi-neers coordinate expan-sion joint specifications with their purchasing department to reduce turn-around time, redun-dant paperwork, and correspondence. The site provides online design tools and also feature credit card and traditional purchase order trans-action capability for quick and easy processing.
Visitors can also create customized accounts, save and edit inquiries, review history as well as price and order additional types of expansion joints such as ASME Section VIII Code expansion joints, boiler seals, and eventually expansion joints for GTX and FCCU applications.
It is the vision of EJS to provide the best cus-tomer service experience by extending many convenient channels to customers worldwide.
Clamshell bellows offer a quick and easy solution to boiler seal replacements
Rectangular Flex-250 fabric expansion joint for a chemical processing plant
Piping Analysis
I
n 2003 Expansion Joint Systems, Inc. (EJS) teamed up with Piping Analysis Inc., (PAI) to pro-vide complete expansion joints and comprehen-sive analysis of your expansion joint, and piping system. PAI is a full-service mechanical, machin-ery, and engineeringcompa-ny that specializes in piping, mechanical machinery, and civil/structural design prob-lems. PAI has vast experi-ence in analyzing the flexi-bility of and stresses associ-ated with piping and relassoci-ated structures. Their expertise combined with their propri-etary programs, written
and developed by PAI, have consistently produced reliable answers to complicated prob-lems for many satisfied cus-tomers.
Pipe Stress
The analysis of piping stress and flexibility is a crucial
ele-ment of a successful and efficient plant design. We realize that unexpected mechanical problems requiring frequent maintenance or even shut-downs are often caused by an insufficient level of quality in the design of the connected pip-ing system and related struc-tures such as expansion joints. Efficiency, and therefore prof-itability suffer, leading ulti-mately to permanent damage and high costs for repair and maintenance. PAI offers expansion joint and spring support surveys as well as a wide range of engi-neering services from system design to project scheduling.
Finite Element
Analysis
For detailed analysis of piping components such as expansion joints, tube sheets, nozzle con-nections, flanges, lifting lugs, or any other object, structural or otherwise, which may be under undesirably heavy loads and/or stresses, we use finite element techniques and software. PAI also creates 2D and 3D models to predict mechanical stresses due to pressure, temperature, and other applied loadings, as well as vibrational frequen-cies and heat transfer calculations.
Heat Transfer and
CDF/Fluid Flow
To aid in process analysis and mechanical stress related problems, PAI provides heat transfer analysis. PAI have the capability, through experi-ence and PAI proprietary programs, to use proven analytical methods as well as the latest computational fluid dynamics and heat transfer techniques.
PAI-PIPEFLOW is PAI’s proprietary program used to calculate liquid, gas, or steam flow rates, pressures, pressure drops, flow velocity and total lengths of piping for pipe elements inside or out-side of networks.
Vibrations
Vibrations can play a large role in maintenance costs and lead to expansion joint, machinery, and piping system failures. Through years of experi-ence, training, proprietary techniques, and spe-cialized software, PAI has the capability to solve problems. For more information about Piping Analysis Inc. please visit their website at www.paiengineering.com
Other Engineering
Services
I
n addition to failure analysis, PAI offers plant design; including civil and structural analysis, con-struction drawings, design review, project sched-uling, and construction follow up.Global Piping Analysis
As a global company with manufacturing facil-ities around the world, EJS strives to offer many value-added services to complement our prod-ucts. Our relationship with PAI allows us to extend our services beyond our expansion joints to better support our customers worldwide. Originally serving the local Gulf Coast region (Louisiana, Texas, Mississippi), PAI has seen
tremendous growth in its business and now solves complex engineering problems all over the world.
Field Services,
Emergency Delivery,
and Refurbishment
In early April of 2003 Expansion Joint Systems, Inc. (EJS) was contacted by a large refinery in Texas City to provide a solution for a leaking fab-ric expansion joint installed in the flue gas inlet duct to the flue gas cooler. The catch was the repair had to be complet-ed while the refinery was in operation.
The flue gas line was a 90” (228.6cm) diameter refractory lined duct with
a skin temperature of approximately 2500F
(1210C). The leaking joint was installed at a 450
angle at an elevation of around 15ft. (3.8m) above ground level. The fabric was leaking in one area at the top of the joint; catalyst and 12000F
(649C) flue gas was escaping from the failed area.
EJS designed a tandem bellows clamshell that com-pletely enclosed the leaking fabric expan-sion joint while allowing the flue gas duct to cycle without interruption. The confined location of the expansion joint determined that the replacement joint had to be installed in sections over the existing joint. The
complete clamshell (shown below) was dropped down over the fabric and welded in place. Total installation time was 14 days, working 10-hour shifts by an installation team comprised of local contractors, refinery staff, and EJS technicians
and engineers.
EJS has the engineering, manufacturing, and installation teams ready to address your repair needs immediately. Service. It’s not just a word at Expansion Joint Systems; it’s our way of doing business.
F
or two decades EJS has established alliances with world leaders in the petrochemical, oil, refining, power, marine, industrial fabrication industries as well as a variety of OEM manufac-turers.These relationships have evolved into what is recognized today as EJS Global Sales and Manufacturing; a network that extends into nearly every region of the world.
EJS Global Sales and Manufacturing consists of international sales and engineering offices around the world combined with local manufac-turing by specialized sub-contracting facilities. The sales and engineering offices are staffed with direct EJS personnel reporting and liaising with EJS-US. The staff, sales and engineering support are predominately local personnel to provide
easy communication with customers and the facilities within their territory. Each international office controls their regional sales force located in smaller territories within the international regions.
Going global doesn't mean we are sacrificing quality or our commitment to customer satisfac-tion. EJS-US continues
to retain all design, engi-neering, and responsibility for our inter-n a t i o inter-n a l offices while providing the more special-ized components
of the expansion joint assembly directly from our U.S. manufacturing facility. Complex and spe-cial bellows are always supplied for final fabrica-tion by EJS-US as well as other complex struc-tures when required.
Each product carries the EJS label and all responsibility for the final product including war-ranty remains with EJS-US. Although each inter-national office is entirely its own entity (incorpo-rated or registered in it’s operating country), EJS has financial, technical and legal authority over each office. Privately owned and operated, the various fabrication facilities used by EJS and our inter-n a t i o inter-n a l offices are chosen for their ability to provide quality fabrication within the industry and produce EJS products of the highest standards. Long standing agreements are established to provide fabrication of our products using typical EJS processes and techniques. Each manufactur-er is ASME cmanufactur-ertified. EJS provides project
engi-neers and quality control staff to each facility for every project that is fabricated providing a smooth completion of the project to EJS stan-dards and ensuring our customers complete sat-isfaction.
From quotation to design through inspection and shipment, EJS provides superior service to our customers worldwide.
Our international clients receive the same design and engineering specialists required for their project from the USA design team while benefiting from lower fabrication costs offered by local manufacturers. Our customers can feel confident that EJS will be involved directly in the fabrication facility throughout the manufacturing process.
EJS Canada
EJS Canada manufacturers many large, com-plex expansion joints such as our Cat Cracker expansion joints for many of our customers in Canada, South America and the United States. EJS Canada, located in Quebec, offers unlimited
transport access to an international seaport. This ASME certified facility offers limitless fabrication capacity and quality workmanship at
competitive prices. EJS Canada/Valtech Industries is a world leading custom metal fabri-cator specializing in FCCU equipment, refractory, pressure vessels, and many other related struc-tures.
Our sales and engineering office for EJS Canada is located in Ontario. This facility pro-vides smaller standards fabrication for EJS-US and operates its own bellows fabrication facility.
EJS Asia Pacific
(EJSAP)
EJSAP has main sales & engineering offices located in Sydney, Australia and Singapore. Each office manages various territorial sales agents throughout the Asia Pacific region with manufac-turing in Kuala Lumpur, Malaysia. Our EJSAP manufacturing partner has several facilities throughout Southeast Asia and provides quality
prod-ucts and services for their customers in the oil, gas, petrochemical, and power gen-eration industries.
EJSAP manufacturing is an ASME Section VIII manufacturing facility providing equipment to most oil companies in the area and beyond Malaysia. Their modern and well-managed facilities rival any high standard manufac-turer in the region. Together with EJS supervision, the expansion joints fabricated in this facility are of the finest quality and EJS is proud to have these products bear the EJS name.
EJS Europe
(EJSEU)
Our main European office in Florence,
Italy manages our Western European, Middle Eastern and Russian sales offices providing a direct link to EJS-US.
Our Eastern European sales offices have been trading in the region for over 22 years and include offices in the Czech Republic, Croatia, Hungry, Poland,
Yugoslavia and the United Kingdom. These direct offices located throughout Europe, provide an excellent channel to EJS-US.
Manufacturing for EJS Europe and the Middle East is provided by our partner located in Bucharest, Romania. Established in 1897, this ASME facility is a globally recognized manufac-turer of process equipment: reactors, heat exchangers, columns, air coolers, and large pres-sure vessels.
The company's facilities consist of several office buildings, workshops and warehouses on 30 acres (122,500 sq.m) providing limitless
fabrication capacity.
EJS South
America
EJS-SA sales and manufacturing is located in Valencia Venezuela. Since 1976 this 2.7 acre (11,000 sq. m.) facility has been manufacturing pressure vessels and related equipment in accordance with the ASME standard.
EJS GLOBAL OFFICES
www.ejsus.com
Australia - Telephone: 61-2-9838-4456 • Fax: 61-2-9838-4457 • E-mail: [email protected] • Website: www.ejsap.com Europe (Italy) - Telephone: 39 (055) -2349635 • Fax: 39 (055) -2349914 • E-mail: [email protected]
Europe (UK) - Telephone: 44 (1332) 700053 • E-mail: [email protected] ABB - PT Pal Indonesia
Alstom Power (Australia, Indonesia, USA) Baharat Heavy Electricals
Bariven S.A. Bowman Power Systems
Bechtel Corporation BP Refinery Bufete Industrial Cia. Cervecera De Zacatecas
Cerrey S.A. De C.V. Chennai Petroleum Corp Chevron Daelim Engineering Co. Ltd.
Dahbol Power Plant Doosan Machinery
Deltak Corporation Fluor ExxonMobil Hyundai Heavy Industries
Irving Oil
John Zink Company
Kawasaki Heavy Industries Kellogg/Brown & Root
Larsen & Toubro Nhumo S.A. De C.V.
Pertamina Refinery PDVSA
Philipinas Shell Petroleum PT Heat Exchangers Indonesia Reliance Petroleum
Salcon Power Corp Siemens Westinghouse Stone & Webster Engineering Sumitomo Heavy Industries Shell
Thai Polycarbonate Thai Petrochemical Industries Valero Refining
Vogt Power International
