U.S. Bellows, Inc. recently manufactured three 12′ – 0″ x 8′ – 0″ rectangular expansion joints designed at 5 PSIG and 650 °F. The expansion joints are fabricated with full radius corners which allow for an increased cycle life. The bellows are formed from Inconel® 625 SB-443 GR. 1 and the rest of the assembly is fabricated from A516-70. The long seam welds were 100% x-rayed. A 100% dye-penetrant test was performed on the attachment welds.
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U.S. Bellows, Inc fabricated and installed a clam shell bellows for a shell and tube heat exchanger. The clam shell bellows is designed and fabricated per ASME VIII Div. 1 appendix 26. It has a 14″ diameter and was designed at 150ºF and 150 psig. In order to detect any leaks, prior to and following forming, the heat exchanger and its welds were subjected to a series of tests such as the dye penetrant test (100%), X-ray test (100%) and air test.
U.S. Bellows, Inc., the expansion joint division of Piping Technology & Products, Inc. rushed to an emergency call of an Alaskan petroleum firm. The firm called upon U.S. Bellows’ 24 x 7 Quick-Turn/Emergency service to aid them in the immediate replacement of a defective, 48″ diameter expansion joint when their G417 Pump failed suddenly during the plant startup.
The timeline of events demonstrates the quick engineering and manufacturing response from U.S Bellows:
07/21/00 (Friday) 5:30 p.m., U.S. Bellows receives an emergency call.
07/22/00 (Saturday) U.S. Bellows/ PT&P builds the 48″ diameter expansion joint and ships it to location on the same day.
07/23/00 (Sunday) The 48″ diameter expansion joint designed and built by U.S. Bellows/PT&P was installed at customer’s location.
The customer expressed great appreciation for the extraordinary efforts put forth by the individuals at U.S. Bellows. The on-call engineering and manufacturing team demonstrated its ability and commitment to servicing customers on an emergency basis.
U.S. Bellows is available on a 24 x 7 basis to fulfill any emergency requirements that might arise in the course of plant shut-downs or start-ups. The company has a system of stock bellows which can be used to assemble and ship different types of expansion joints including universal, elbow pressure balanced, and in-line pressure balanced expansion joints. The U.S. Bellows’ “on-call” engineering and manufacturing team is specifically equipped to handle rush and emergency orders. Using unique web and Internet-based technology, the company is able to respond to any emergency requirements within 30 minutes of notification.
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.
U.S. Bellows, Inc., a subsidiary of PT&P, has recently supplied four 72-inch expansion joints required for the piping system of a power plant being built in Zhuhai, China. These large expansion joints will carry the exhaust from the plant’s boiler feed pump turbines.
This critical piping application often requires pressure-balanced expansion joints, but in this case a unique combination of a universal joint in one plane (left side of photo) and a hinged joint (right side of photo) was used.
This photo shows a 42 inch bellows made by PT&P being tested by Leak Detection Specialist Inc. After sealing the bellows a full vacuum is pulled on the inside, then helium is sprayed over the surface of all welds. A pump pulls any gas which leaks to the interior of the bellows to a special mass spectrometer designed to detect the helium. If helium is detected, the point of the surface where it was sprayed is marked for repair. When no leaks are found, the flow rate of helium to the mass spectrometer is measured against a standard for aluminum, in this case 0.000001 cc/sec. Helium molecules are so small, they will penetrate aluminum at a slow rate when the pressure difference of a full vacuum is applied.
A mass spectrometer functions by accelerating a narrow beam of ions of a gas sample through a magnetic field. When they reach the magnetic field, the amount they are deflected depends on their charge-to-mass ratio. In this application the detector is set to record helium ions. In order to measure the flow rate of the helium when no leaks are detected, the entire system is sealed in a plastic “bag”. LDS can measure helium flow rates as small as 0.00000001 cc/sec.