Expansion Joint Data Sheet and Technical Specification for FCC Units

Colaboração de Medeiros e Nunes da Petrobras

1. PURPOSE
This specification establishes the minimum conditions required for design and
fabrication of a packed metallic bellows universal expansion joint for the flue gas system
of the FCCU-Fluid Catalytic Cracking Unit.
The corresponding expansion joint data sheet follows in continuation to this
specification.

2. GENERAL CONDITIONS
2.1. All deviations and exceptions from the specification shall be clearly identified in
the proposal and submitted for approval. Otherwise the proposal will be
considered as full acceptance of the specification, and no work regarding such
non-conformities shall be performed.
2.2. The bidder shall submit information about the size, and thickness of the bellows,
the material of all parts, the design movements, the bellows spring rates, and
overall dimensions of the expansion joint. Constructional details specified in this
technical specification, as well as on the data sheet shall also be submitted.
2.3. Compliance with this specification does not exempt vendor from the responsibility
of supplying any accessories suitable for the intended service.
2.4. Vendor shall guarantee that the expansion joint is free from defects of
workmanship, materials and design for a period of one year from the unit start-up
or two years after shipment, whichever occurs first.
2.5. The manufacturer shall provide a supply list of similar applications in FCC units for
petroleum industry, with, at least, five years of operation.
2.6. The manufacturer shall provide a recommended spare parts list with the proposal.
2.7. The schematic drawing shown on the last sheet of this specification is to be used
as a reference only. Vendor shall provide all the features considered necessary to
achieve the minimum requirements established herein.
2.8. All work shall conform to acceptable practice for refinery and process plant
installations as well as comply with required codes and standards mentioned in
item 3 below. Any conflict between specifications, recommended practices, and
codes or standards shall be brought to the attention of and resolved with the
OWNER before proceeding with the fabrication of the affected parts.

3. CODES AND STANDARDS

The following codes and standards shall apply:
3.1 ASME Code Se II – Materials
3.2 ASME Boiler and Pressure Vessel – Sec.VIII – Div.1;
3.2. ASME Code Section IX – Welding ;
3.3. ASME B16.5 – Pipe Flanges and Flanged Fittings NPS ½ through 24;
3.4. ASME B31.3 – Process Piping;
3.5. ASTM C795 – Standard Specification for Thermal Insulation for Use in Contact
with Austenitic Stainless Steel;
3.6. ASTM E94 – Standard Guide for Radiographic Examination;
3.7. EJMA Standards;
3.8. PETROBRAS Standard N-2 – Anticorrosive Coating of Industrial Equipment;
3.9. PETROBRAS Standard N-133 – Welding;
3.10. PETROBRAS Standard N-1617 – Application of Refractory Castable;
3.11. PETROBRAS Standard N-1728 – “Concreto Refratário”;
3.12. PETROBRAS Standard N-1910 – Castable Lining Design.

4. REFERENCE DOCUMENTS
4.1. Expansion Joint Data Sheet.

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5. GENERAL REQUIREMENTS
5.1. The expansion joint referred to in this specification shall be a universal type
expansion joint with packed metallic bellows and provided with pantographic
linkages.
5.2. The expansion joint shall be cold wall design, with a double layer refractory lining
applied to its inside surface.
5.3. The refractory material shall be specified, supplied and installed according to
PETROBRAS Standards and Specifications. A typical refractory-lined expansion
joint detail is shown on the schematic drawing mentioned in item 2.7.
5.4. A typical packing detail for metallic bellows is also presented on the schematic
drawing above mentioned. Packing requirements are defined in item 6.
5.5. All pressure containing and structural parts shall be in accordance with the
Process Piping Code (ASME B31.3). Special items to be designed by analysis
shall be in accordance with ASME Sec.VIII – Div.1.
5.6. Supplier shall provide any necessary supporting device and lifting lugs to
expansion joint. Supporting device shall be designed for minimum and easy
maintenance.
5.7. Supplier shall supply electronic files of the following drawings and data reports for
installation, maintenance and records purposes:
a) Certified fabrication drawings of the equipment, showing complete longitudinal
section and cross section, overall dimensions, bellows dimensions and details,
bellows spring rates, cold clearances and construction materials of supplied
expansion joint. When transportation bars or rods are supplied, the drawings shall
contain instructions as to removal of such devices prior of plant operation.
b) Calculation report, including: EJMA calculation, FEM – Finite Element Analysis
reports for thermal and structural analysis, whenever this calculation is performed.
5.8. The criteria to establish the design allowable stress shall consider the
accumulated creep damage due to upset temperatures.
5.9. The expansion joint supplier shall provide all necessary data for mechanical
assessment of the existing piping system, considering expansion joint reaction,
such as: spring rate, expansion joint weight, bellows effective area or mean
diameter of bellows corrugations, and geometrical data. The rated movements
and other expansion joint limitations shall also be informed.
5.10. The specified axial, offset and rotation movements shall be available
simultaneously, unless otherwise noted.
5.11. The design life of the expansion joint shall be at least 1,000 cycles at design
condition.
5.12. Internal sleeves shall be installed to minimize catalyst volume trapped in, and the
erosion action of catalyst impingement on bellows. These sleeves shall be
designed so as to avoid interferences caused by lateral deflections and rotations,
and shall not reduce the internal flow area.

6. PACKING AND SEALING REQUIREMENTS

6.1. The spaces between the internal sleeves and the metallic bellows shall be packed
with ceramic fiber blanket insulation. The ceramic fiber insulation shall be installed
in blanket form and shall be in accordance with ASTM Specification C795. The
insulation dimensions shall be determined to avoid temperature above bellows
material limits, and catalyst impingement
6.2. An external protection of woven wire mesh covered with a layer of aluminized
fiberglass or silica cloth shall be provided with the ceramic fiber blanket, for
mechanical sealing and easy handling. Alternative methods may be accepted, but
shall be submitted for approval.
6.3. A heavy duty liner seal shall be provided in order to retain the ceramic fiber
blanket and keep large particles out of the bellows/liner cavity. This liner seal shall
be made of a 309 SS knitted wire hope, covered with a 309 SS hose braid. The

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 liner seal shall be one-piece continuous circular section provided with only one
splice.
6.4. The diameter of the liner seal shall be 1½ times the specified clearance in the
radial direction for the expansion joint in the cold position before preset.
6.5. The liner seal shall be anchored by means of a seal rod, which is a “U” shaped
clip, made of 309 SS, to be annealed after forming. As an alternative two retaining
rings could be used.
6.6. The inner sleeve shall be connected to the shell by means of a conical transition
with a 30° max. lateral angle.
6.7. Each sleeve shall be installed so that its free end is turned towards the expansion
joint flow exit (downstream) end.

7. SPECIFIC REQUIREMENTS
7.1. The expansion joint shall be provided with double ply testable bellows, as follows:
• Each bellows’ ply shall be designed for the full design condition. The
redundant ply shall guarantee the performance and sealing of the expansion joint
in case of primary ply failure.
• Each expansion joint bellows shall be provided with a pressure sensor
between the plies, for testing and detection of internal ply failure.
• The double ply assembly shall be configured to avoid galling or any
obstruction that interfere on pressure reading.
7.2 Metallic bellows skin temperature shall range from 250°C to 450°C. Manufacturer
shall provide proper external and internal blanket thermal insulation in order to
achieve this range. This blanket shall be shop applied.
7.3 Supplier shall provide means of monitoring the bellows skin temperature.
7.4 Composite bellows plies are not allowed.
7.5 Bellows material shall be ASTM B433 alloy 625 LCF.
7.6 Bellows minimum thickness: 1.27 mm.
7.7 The number of convolutions per bellows shall be not less than three.
7.8 Bellows shall be protected by removable external covers with 6mm minimum
thickness.
7.9 Whenever requested, equalizing or reinforcing rings shall be used, otherwise the
manufacturer must justify why they are not used.
7.10 Besides equalizing the movement between the bellows, the pantographic linkage
shall also be designed to withstand the total weight of the intermediate pipe spool.
7.11 Torsion loads (movements) shall not be transferred to metallic bellows.
7.12 Expansion joints shall be provided with movement indicators.
7.13 The expansion joint design shall be such as to allow easy access to any bellows,
for inspection and maintenance purposes.

8. TAGGING
8.1. Expansion joint tag: ????

9. FABRICATION, EXAMINATION, INSPECTION AND TEST REQUIREMENTS

9.1. During the expansion joint fabrication and tests, inspection may be made by
OWNER or by OWNER designated third part, to determine work in progress and
check specification compliance.
9.2. Bellows shall be formed from longitudinally buttwelded cylinders. The maximum
number of bellows longitudinal buttwelds for the expansion joint concerning this
specification shall be 4. Adjacent longitudinal welds shall be no closer than 130
mm apart.
The finished longitudinal welds are to be of the same thickness (-0% +10%) and
same surface finish as the parent material. Circumferentially welded seams shall
be prohibited.
9.3. All expansion joint welds shall be full penetration and smooth finished, with no
undercut or lack of fusion.

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9.4. All retaining pressure welds shall be submitted to 100% radiographic examination
or, alternatively, 100% ultrasonic examination, where the ASME B31.3 Code
allows.
9.5. All internal welds, fillet and attachment welds shall be submitted to dye penetrant
examination.
9.6. Bellows longitudinal welds referred to in item 9.2 shall be 100% radiographed and
liquid-penetrant examined on outside and inside surfaces, prior to forming. Liquid
penetrant examination on all surfaces shall be repeated after forming.
9.7. When the surface examined is of austenitic alloy steel or nickel-iron-chromium
alloy materials having a design metal temperature above 400 °C, the liquid
penetrant material shall be tested for sulphur content and the surface shall be
properly cleaned after completion of testing.
9.8. Welding procedure and qualification certificate shall be submitted for OWNER
approval.
9.9. The fabricator shall scarf and otherwise prepare the welding ends that are to be
welded by others.
9.10. All weld bevels on the ends of carbon or ferritic alloy steel piping components that
are to be welded by others shall be coated on the inside and outside for a
distance of 76 mm from the end of the component with a suitable protective
product.
9.11. The welding process shall be according to ASME Section IX.
9.12. The fabricator shall provide heat treatment procedures, taking into account the
risk of sensitization and sigmatization of the austenitic stainless steel parts.
9.13. Mill test reports shall be submitted for all materials and weld consumable.
9.14. Upon completion of all fabrication, the fabricator shall pressure test the expansion
joint assembly.
Before pressure testing, all internal surfaces of the expansion joint shall be
cleaned so that it will be free of welding slag and flux, weld rod studs, loose scale,
dirt and debris. Potable water with less than 5 ppm chlorine shall be used for
hydrostatic testing. The expansion joint shall be drained and dried.
9.15. After pressure testing all openings shall be closed, sealed or covered to prevent
access of water, dirt or corrosive dusts and vapors during shipment and site
storage.
9.16. All defects requiring repair shall be corrected in accordance with the applicable
code.
9.17. The expansion joint shall be painted according to OWNER Standard, up to 76 mm
from each expansion joint end. Special high temperature indicating painting shall
be used.
9.18. Refractory lining application shall be according to PETROBRAS standards N-
1617 and N-1910.
9.19. Inspection, examination and tests shall be according to ASME B31.3 Code and
EJMA Standards. Expansion joint shall be tested at shop.
9.20. For 304 SS parts, the welds shall be with ER-308H electrodes 15/16 coating and
ferrite control to be 3% to 8% FN Delong examination.

10. INSTALLATION REQUIREMENTS

10.1. The expansion joint shall be delivered with shipping devices for transportation,
temporary supports during installation, and field pressure test.
10.2. Spare parts shall be delivered clearly identified with name and part number.
10.3. The expansion joint shall have a name plate of corrosion resistant material
informing: tag number, service, operating and design conditions, pressure test,
manufacturer, purchase order number, year of fabrication and total weight.
10.4. Two flow direction indicators shall be placed on the external shell, 180° apart from
each other.

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 SCHEMATIC DRAWING – REFRACTORY LINED PACKED MTALLIC BELLOWS
EXPANSION JOINT

MATERIAL LIST
ITEM DESCRIPTION MATERIAL
1 Bellows ASTM B443 Alloy 625 LCF
2 Thermal insulation By manufacturer
3 Woven wire mesh AISI 304
4 Removable cover Carbon steel
5 Pipe ASTM A672 Gr. C60 Cl.12
6 76 mm thk. refractory lining Class “A” insulating refractory,
according to PETROBRAS standard
N-1728. Refractory anchor to be square
head type studs, made of 304 SS.
7 Blanket insulation Ceramic fiber
8 Heavy duty liner Seal AISI 309
9 “U” clip AISI 309
10 Hexagonal mesh AISI 304
11 25 mm thk refractory lining Class “A” antierosive refractory,
according to PETROBRAS standard
N-1728, similar to RESCO AA-22
12 10 mm thk internal sleeve ASTM A240 TP304
13 Woven wire mesh AISI 304

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 EXPANSION JOINT DATA SHEET
1. PURPOSE
This data sheet establishes the design data of an expansion joint for the flue gas
system of the Fluid Catalytic Cracking Unit.

2. REFERENCE DOCUMENTS AND STANDARDS

3.1 EXPANSION JOINT TECHNICAL SPECIFICATION.

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1 TAG Identification To be informed latter
2 Quantity To be informed latter
3 Expansion Joint Type Universal type expansion joint with
packed metallic bellows provided with
pantographic linkages
4 Diameter (mm) To be informed latter
5a Fluid Description GAS AND CATALYST FINES
5b Density (kg/m3) –
5c Flow Rate (kg/s) To be informed latter
5d Flow Direction To be informed latter
6a Operating Conditions Pressure (kgf/cm²g) To be informed latter
6b Temperature (°C) To be informed latter
6c Room Temperature (°C) To be informed latter
7a Design Conditions Pressure (kgf/cm²g) To be informed latter
7b Temperature (°C) To be informed latter
7c Life Cycles 1000
8a Emergency Conditions Pressure (kgf/cm²g) To be informed latter
8b Temperature (°C) To be informed latter
8c Duration 10 h/year
9 Test Pressure (kgf/cm²g) To be informed latter
10a Maximum Installation Axial Compression (mm) To be informed latter
10b Movements (((mm)
Axial Extension (mm) To be informed latter
10c Lateral (mm) To be informed latter
10d Angular (deg.) To be informed latter
11a Maximum Design Axial Compression (mm) To be informed latter
11b Movements Axial Extension (mm) To be informed latter
11c Lateral (mm) To be informed latter
11d Angular (deg.) To be informed latter
11e Number of Cycles 1000
12a Operating Fluctuations Axial Compression (mm) To be informed latter
12b Axial Extension (mm) To be informed latter
12c Lateral (mm) To be informed latter
12d Angular (deg.) To be informed latter
12e Number of Cycles To be informed latter
13 Rods (Tie/Limit/Control) Yes see note
14 Pantographic Linkage Yes
15 Internal Sleeve Yes
16 External Cover Yes
17 Equalizing and Reinforcing Rings By manufacturer
18 Purge Connections No
19 Shipping Devices By manufacturer
20 Internal Lining Yes (See note)
21 External Insulation No
22 Ends (Welded / Flanged) Welded
23a Dimensional Limitations Overall Length (mm) To be informed latter
23b Outside Diameter (mm) To be informed latter
23c Inside Diameter (mm) To be informed latter
24a Spring Rate Limitations Axial (N/mm) By manufacturer
24b Lateral (N/mm) By manufacturer
24c Angular (N.m/deg.) By manufacturer

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25 Installation Position (Horiz or /Vert.) To be informed latter
26 Vibration Amplitude / Frequency of the piping To be informed latter
27a Materials of Bellows ASTM B-433 Alloy 625 LCF
27b Construction Material pipe specification As specified above
27c Flange Specification As specified above
27d Internal Sleeve ASTM A 240 Gr. 304H
27e Cover Carbon Steel
27f Rods By Manufacturer
27g Equalizing Rings By Manufacturer
27h Reinforcing Rings By Manufacturer
27i Internal Lining See note
28a Quality Assurance Code ASME B31.3 and EJMA
28b Requirements Additional Requirements To be informed latter
28c Technical Specification As specified above

NOTES:
1. The manufacturer shall take into account dimension limitations inherent to the available
room.
2. The expansion joint shall be cold wall, packed metallic bellows type, in accordance with
the technical specification as specified above.
3. Tie rods shall be provide, to avoid that pressure thrust and spring loads be transferred to
the adjacent equipments.
4. Final dimensions shall be established with the OWNER.
5. The diameter and arrangement of the tie rods will be checked by the OWNER to make
sure that expansion joint will achieve its purpose.
6. The expansion joint shall be supplied with suitable allowance concerning the length, for
field adjustment.
7. Manufacturer shall establish the expansion joint transverse dimensions taking into account
the installation of tie rods.
8. The procedure for refractory lining application shall be submitted to OWNER for approval,
and all application work shall be performed under supervision of OWNER technicians.
9. Duration of the emergency conditions: 10 h/year.
10. Pressure and temperature emergencies should not be considered as occurring
simultaneously.
11. Manufacture shall inform the expansion joint spring rates.

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 Schematic drawing of a Universal type expansion joint with packed metallic bellows
provided with pantographic linkages

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