Our field service team is available 24/7 during your plant turnaround!
Our team can assist with plant walk-downs to assess your plant for maintenance, repair or replacement of expansion joints and pipe supports
Our engineers are available day or night for guidance on placement, materials, finishes, etc.
Our field service team will guide you through installation, start-up, and replacement
We stock over 1500 bellows, over 100,000 lb. of insulation materials, over 30,000 spring coils, and over 1 million pounds of standard items
Afterwards, receive training to monitor, identify potential failure, learn correct size and selection of expansion joints and pipe supports per application
We can develop a data book of existing pipe supports and expansion joints and their conditions in order to identify potential maintenance issues in upcoming turnarounds.
View Some of Our Emergency Projects
Refurbishment of 4″ Dia. Expansion Joint in One Day
This expansion joint received in the morning and shipped to the customer the very same day.
Same Day Turnaround During Emergency Shutdown
Same day delivery enabled the customer to resume operations with minimum loss of time and production.
Quick Turnaround of Refurbished Expansion Joint
A service call came in when a leak was discovered resulting from a crack in the bellows of a pressure balanced elbow expansion joint. New bellows were fabricated, carbon steel root rings and cover bolts were replaced, and the unit was back in service in high pressure turbine crossover piping within a few weeks.
Need to talk with one of our field service technicians? call us at (281) 241-9418 Or fill out the emrgency request form
We have an inventory of stock bellows for your quick-turn/emergency requirements. Contact us now if you need a replacement expansion joint. We can run it through our expedited manufacturing line using a prefabbed bellows and get it to you within 1-2 days in some cases.
Using our inventory, we can quickly assemble and ship a variety of expansion joints including single, single tied, universal, elbow pressure balanced and in-line pressure balanced expansion joints. Stock bellows are available from 2″ to 24″ diameter and in three pressure values: 85 psig, 150 psig and 300 psig.
Emergency Shutdown: Replacement of a Metallic Universal Expansion Joint for a Chemical Plant in Wisconsin
One of U.S. Bellows’ customer’s existing expansion joint failed and caused a plant shut down. They required an immediate replacement joint. This universal expansion joint order was placed, designed and fabricated in just one day. The order came in at 8:30 am on Saturday, Labor Day weekend and was shipped at 4:00 pm, which minimized the time of the plant shut down. This universal expansion joint is 96″ in overall length, 20″ inside diameter and can absorb 3.25″ lateral movement. A 100% dye-penetration test and a hydro-test were performed to ensure quality.
Three Day Emergency: 40″ Clam Shell Expansion Joint Fabricated for a Chemical Plant in Texas
Within a three day span, U.S. Bellows, Inc., fabricated a 40″ I.D., single coded, clam shell expansion joint for a chemical plant in Beaumont, Texas. The chemical company utilized U.S. Bellows’ 24 x 7 Quick Turn/Emergency service. After the representative from the chemical plant completed the online form, the U.S Bellows’ on-call team was immediately paged. Three days later the bellows had been successfully fabricated, welded to an A516-70 heat exchanger shell and shipped to the chemical plant to resume operation. The bellows was fabricated from A240 tp 321 SS and designed at 50 PSIG and 750°F. In order to detect any leaks in the weld, the bellow’s long seam weld was 100% x-rayed and its attachment weld was 100% dye-penetrant.
U.S. Bellows, Inc. is comprised of an accomplished team of expansion joint specialists, including engineers, quality control specialists, and experienced shop fabrication personnel that are ready to serve your expansion joint needs. Our staff, as a whole, represents a combined experience of over 600 years.
Our manufacturing team, engineers, and field service team work together to provide optimum solutions for expansion and contraction in your piping system. With two shifts of employees in our manufacturing facility, we are working around the clock to ensure that your expansion joints are efficiently fabricated to your specific design requirements and delivered within the time frame you have requested.
Below are a few members of our dedicated team who are committed to providing quality service for each and every one of our valued customers:
Why choose U.S. Bellows for all your expansion joint needs?
Engineering & Design
- Per EJMA Standards (Proud member since 2002 with representation on both the technical and management committees)
- Per Latest Revisions of the ASME B31.1, B31.3 and Section 8, Division 1
- ASME U-Stamp, R-Stamp and NS Certified, ISO 9001:2008 Certified
- Full In-house Design Software and Finite Element Analysis Capabilities
- 24-hour Emergency Service and Field Services Available
Manufacturing Capabilities & Facility
- Roll bellows from 2″ to 138″ in diameter and .010″ to .500″ wall thickness
- Stock bellows and material on-site
- 5x the Resources with subsidiaries, PT&P, SWECO Fab., Pipe Shields and Fronek Anchor/Darling
- More than 450,000 sq. ft. of covered shop space and 35 acre property
- Located near the ship channel (one of the largest ports in the U.S. and in the world)
Quality Control & Assurance
- QA/QC Approval: UOP and GE / Stewart and Stevenson
- Manufacturing Qualifications: ASME Section IX, AWS D1.1 and MIL-STD-248
- SASOL QA Plan: 100% X-ray, 100% Dye Pen., Hydro-test, Pneumatic Test and PMI
- Product Testing: Helium Leak Testing, Fatigue Testing, Burst Testing, Ultrasonic and Radiography Testing
- In-House Training: Welding School, JQ/QC Training Courses, Expansion Joint Application Classes and Fabrication Classes
- Four meetings a week and constant communication amongst engineering, manufacturing and management teams
- Continuing to expand facility and add new members to the U.S. Bellows team
Panoramic View of U.S. Bellows Manufacturing Facility
Do you have a plant turnaround scheduled or planning one in the near future? PT&P is prepared to be there for you throughout the entire process. From planning, to execution, and follow-up, we have what it takes to accomplish a successful plant turnaround.
Prior to Your Turnaround:
- Call our field service team to assist with plant walk-downs to assess your plant for maintenance, repair or replacement of pipe supports and expansion joints
- Contact our quotations department for immediate pricing on pipe supports, expansion joints, or auxiliary steel needed during the turnaround.
- Consult our experienced engineers for guidance on support placement, materials, finishes, etc. to ensure optimum life of the supports.
During Your Turnaround:
- Use our field service team to guide you through installation, start-up, and replacement to safely and efficiently handle your turnaround.
- For quick delivery, PT&P stocks over 1500 bellows, over 100,000 lb. of insulation materials, over 30,000 spring coils, and over 1 million pounds of standard items
- Receive training to monitor the supports, and identify potential failure, in order to prevent unplanned turnarounds in the future.
- Learn correct size and selection of pipe supports and expansion joints per application for any post-turnaround resolutions.
- Call on our field service team to develop a data book of existing pipe supports and expansion joints and their conditions in order to identify potential maintenance issues in upcoming turnarounds.
Metallic Expansion Joint Refurbished in 2 Days
A rectangular metal expansion joint was refurbished on an emergency basis for a local chemical plant. Upon arrival, it was acid washed and dye-penetrant examined for any cracks. View the full Article.
Refurbishment of 54" Pressure Balanced Elbow Turbine Crossover Expansion Joints
U.S. Bellows, Inc. refurbished two pressure balanced elbow expansion joints with a quick turnaround for a power generation plant during outages. They are designed for high pressure turbine crossover piping. The first 54″ outside diameter expansion joint leaked from a crack in the bellows causing an unscheduled outage. View the full article.
4" Single Expansion Joint
This expansion joint was received in the morning and shipped to the customer the very same day. The bellows, liner and cover were replaced and the carbon steel parts were sand blasted, cleaned and painted. A dye-penetrant test and hydro-test to 518 PSIG were performed prior to shipment. View the full article.
Same Day Turnaround Service on an 8" Single Expansion Joint
This expansion joint was received in the morning, refurbished by adding new bellows and limit rods, and then shipped the very same day. New 321 stainless steel bellows were fabricated and the existing flanges were reused by sandblasting and then painting for corrosion protection. View the full article.
This week’s featured article is on expansion joint burst testing. The objective of a burst test is to determine the ultimate pressure resistance that a bellows can absorb prior to failure. Burst tests help determine the margin of safety and safety factor to be used in a specialized bellows design. During a burst test, hydrostatic pressure is slowly increased until failure occurs, which usually happens in one to two hours. Burst testing is conducted at ambient temperatures to determine a bellows pressure rating. We follow all the necessary safety precautions for personnel involved, such as placing the bellows in a high strength steel cage and using a safety shut-off switch. Based on the burst test results, a safety factor is applied, thus establishing the ultimate pressure rating.
The video shows an expansion joint bellows being cycle tested through a specified design movement of 1-1/4″ to verify the calculated life span of 30,000 cycles. The number of completed cycles is recorded throughout the duration of the test. U.S. Bellows routinely performs this test to confirm designs and ensure a high quality product. We do extensive expansion joint product testing such as x-ray, burst, hydrostatic, ultrasonic, radiography, fatigue, PMI, pneumatic, magnet particle and helium leak testing depending on customer specifications. Each bellows and expansion joint unit goes through in-process quality control using a system of travelers, and a final in-house dimensional inspection is performed prior to shipping.
U.S. Bellows has extensive experience in providing quick turn emergency services during unexpected shut-downs and planned turnarounds. We provide expansion joint on-site services, installation supervision, inspection, problem resolution, repair, refurbishment and replacement.
U.S. Bellows has a system of stock bellows and an “on-call” engineering and manufacturing team to meet any of your quick turn and emergency requirements.
For the quickest response, use our online emergency form. We guarantee a response to your request within 30 minutes.
54″ Pressure Balanced Elbow Turbine Crossover Expansion Joint Refurbished with a Quick Turn Around
U.S. Bellows, Inc. refurbished two pressure balanced elbow expansion joints with a quick turnaround for a power generation plant during outages. They are designed for high pressure turbine crossover piping. The first 54″ outside diameter expansion joint leaked from a crack in the bellows causing an unscheduled outage. View the full article——————————————————————————————————
Metallic Universal Expansion Joint for a Wisconsin Chemical Plant's Emergency Shut Down
One of U.S. Bellows’ customer’s existing expansion joints failed and caused a plant shut down. They required an immediate replacement joint. This universal expansion joint order was placed, designed and fabricated in just one day. The order came in at 8:30 am on Saturday, Labor Day weekend and was shipped at 4:00 pm, which minimized the time of the plant shut down. This universal expansion joint is 96″ in overall length, 20″ inside diameter and can absorb 3.25″ lateral movement. A 100% dye-penetration test and a hydro-test were performed to ensure quality.
Metallic Universal Expansion Joint Ready for Shipping
U.S Bellows, Inc. is now offering a new web-based 24×7 instant response service in order to fulfill requirements in emergency/ quick-turn situations.
The web-based 24×7 Quick-turn/ Emergency service is an invaluable and unique addition to the company’s variety of services. The quick turn/ emergency form found at http://www.usbellows.com/emergency.html is easy to read and simple to complete. Upon submission of name, email address, telephone number, fax number and brief and detailed problem description, the U.S. Bellows’ “on-call” engineering team is immediately notified via electronic pager and e-mail. U.S. Bellows’ engineer contacts the customer within 30 minutes to obtain further information and to provide a problem assessment. Once an action plan has been formulated, the U.S. Bellows’ engineer does the necessary design work and then assembles an emergency manufacturing team to build the product. This process, from notification to shipment, can be done by U.S. Bellows in less than 24 hours.
Since the creation of the new online 24×7 quick turn/ emergency form, there have been a number of customer success stories. Customers have a strong appreciation for the ability of U.S. Bellows to provide immediate attention and service to emergency matters. The web-based 24 x 7 Quick-turn/Emergency service is one of the innovative technology-based services provided by U.S. Bellows.