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Expansion Joint Systems, Inc.
C o m p a n y
&
P r o1 d u c t
O v e r v i e w
Asia Pacific • Canada • Europe • Mexico • Middle East • South America • United States
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FCCU (Fluid Catalytic Cracker Units): Lined, Unlined, hot wall, cold wall, self equalizing and multi-ply monitored bellows.
Expansion Joint Systems Our name says it all. Expansion Joint Systems (EJS) designs, markets, and manufactures expansion joints and piping solutions. EJS produces 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 technology and worldwide service. Today, we continue to offer consistent customer value, 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 products 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. EXPANSION JOINT SYSTEMS
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.
Customer Commitment Our commitment to quality starts at the quotation stage. Utilizing state of the art computers and software, including Finite Element Analysis & Parametric Technology, we can help you specify and layout the correct joint for any given application. All expansion joints are computer designed using software developed by EJS engineers 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 developing new bellows technology. The EJS Commitment doesn’t stop with the design and manufacturing of the unit. We are
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 markets. 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 fabric expansion joints, but we have become specialists in highly engineered units such as:
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CCR (Continuous Catalytic Reforming); These units require detailed analysis due to the light wall, high alloy shell design. GTX (Gas Turbine Exhaust); High temperature fabric expansion joints, including Hot to Cold, Cold to Cold and Hot to Hot designs. Styrene: These expansion joints incorporate solution annealed 800H bellows to accommodate extremely high temperatures without refractory lining. LNG: Cryogenic designed expansion joints with vacuum jacketed piping.
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Expansion joint after final inspection.
3D model of a 26-3/8" (67cm) diameter universal round to rectangular expansion joint with 2 ply testable indicators for a major refinery.
Expansion Joint Systems Our design and engineering team uses the most innovative technology and design software available today. All EJS production drawings are produced using Parametric Technology that provides 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 customers. EJS also uses Finite Element Analysis (F.E.A.) as a standard part of our design process. We have the ability 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
EXPANSION JOINT SYSTEMS
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
is often overlooked, but is a common area of failure 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 discussed on page 7. As a technologically progressive company, EJS‘s main production plant utilizes state of the art welding technology with all personnel qualified to ASME standards. The bay shown in this photo has the ability to lift 20ton units and has a hook clearance of 30 feet. EJS is qualified to produce ASME section VIII, Division 1 expansion joints and
expansion joint, with no surprises in service. EJS also supports projects worldwide through our EJS global offices and manufacturing facilities. In addition to our main manufacturing facility in the United States, we also have manufacturing capability in Canada, Malaysia, Romania and Venezuela. More details about our EJS global can be found on page 9.
Customer Seminars
used methods at EJS. This type of attention to detail pays great dividends assuring our customer of a well-designed, completely functional
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The EJS team has produced various presentations and lunch & learn seminars on applications, in-depth engineering and special product discussions. We would be pleased to visit your facility to present an educational training seminar for your engineers, planners and purchasing personnel. Our company also offers customized software that you can use to help develop your designs and piping layouts.
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Hex mesh inside a hot wall FCCU expansion joint
Whether
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 complex expansion joints. We manufacture both metal and fabric expansion joints from 2" (5cm) nominal diameter to 240” (7m), process temperatures 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 movements. These types of expansion joints are generally found in petrochemical and oil refineries, styrene processing plants, C.C.R. and gas turbine
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Refractory lined cold wall FCCU expansion joint with pantographs
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 deliveries.
EJS has 20 years of experience designing and manufacturing FCCU expansion joints. These expansion joints are exposed to high temperatures (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 specification for FCCU joints is the UOP specification. 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.
Fluid Catalytic Cracking Unit Expansion Joints Expansion joints used in FCCU service are some of the most critical and complex types of expansion joints manufactured. For this reason, the choice of manufacturer should be carefully considered.
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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, pressure 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 existing FCCU expansion joints including online clamshell installations with standard and emergency deliveries. Expansion joints for styrene applications must also be designed and manufactured to endure
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18 ft. (5.4m) long cross over tied expansion joint
Installed refractory lined FCCU expansion joint in a flue gas line at a major Texas refinery.
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 temperatures 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
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so each part can be stamped with a unique serial number. This serial number contains a complete 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 quality 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 nondestructive testing such as radiography, ultrasound, mass spectrometer, magnetic particle, hydrostatic and liquid penetrate inspection. We can also include cycle testing, spring rate testing, hardness testing, impact testing, pneumatic testing, helium leak detection and positive material
code analysis that is provided with these highpressure 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 conditions. 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 longitudinal 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
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identification (PMI) as part of our program. All inspectors are certified to ASNT-TC-1A with multiple Level II and III inspectors in house. The design, quality assurance, and manufacturing 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).
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120" (3.5m) diameter Hot to Hot GTX Expansion Joint
High Temperature Fabrics Expansion Joint Systems is also an established manufacturer of fabric expansion joints. As a leader in high temperature fabric expansion joints, EJS remains closely tied to some of the world’s top manufacturers of fabric expansion joints including ISO 9001 certified manufacturers. These relationships 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
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105" (2.6m) diameter weld end refractory lined fabric expansion joint for a major refinery.
growth problems in gas transfer applications. Fabric expansion joints will normally accommodate 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 replacements. EJS designs fabric joints to meet your service requirements and we offer a range of multi-layer fabrics for low to high temperature applications.
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 conditions; a standard membrane (GTX-A) heavy-duty membrane (GTX-B) and severe service membrane (GTX-C). Additionally, we have developed a series of frame designs that can accommodate every
Gas Turbine Exhaust After many years of research, development and testing. EJS has created one of the best GTX
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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 compromise our basic design philosophy to accommodate 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 expansion joints including low temp FLEX 250 and fabric PenSeal Plus boiler seals.
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Rectangular Flex-250 fabric expansion joint for a chemical processing plant
Clamshell bellows offer a quick and easy solution to boiler seal replacements
they are attached to. PenSeals are available in one or two piece clamshell models and in both metal and fabric material,
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 customers worldwide. Our website has been designed to help engineers coordinate expansion joint specifications with their purchasing department to reduce turn-around time, redundant paperwork, and correspondence. The site provides online design tools and also feature credit card and traditional purchase order transaction capability for quick and easy processing.
Low Temperature Fabric Standard Expansion Joints EJS offers standard expansion joints in both metal and fabric. PenSeal Plus penetration seals were developed 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 maintenance personnel. Because they are designed to accept axial, lateral and angular movement these joints lower the stress on the tubes and pipes
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Our FLEX-250 is a high quality fabric expansion joint that can withstand temperatures up to 4800F (2500C) with short peak temperatures to 5720F (3000C) for 16 hours accumulated. FLEX -250 is available in both round and rectangular 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.
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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 customer service experience by extending many convenient channels to customers worldwide.
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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 engineering services from system design to project scheduling.
and developed by PAI, have consistently produced reliable answers to complicated problems for many satisfied customers.
Pipe Stress Piping Analysis In 2003 Expansion Joint Systems, Inc. (EJS) teamed up with Piping Analysis Inc., (PAI) to provide complete expansion joints and comprehensive analysis of your expansion joint, and piping system. PAI is a full-service mechanical, machinery, and engineering company that specializes in piping, mechanical machinery, and civil/structural design problems. PAI has vast experience in analyzing the flexibility of and stresses associated with piping and related structures. Their expertise combined with their proprietary programs, written EXPANSION JOINT SYSTEMS
The analysis of piping stress and flexibility is a crucial element of a successful and efficient plant design. We realize that unexpected mechanical problems requiring frequent maintenance or even shutdowns are often caused by an insufficient level of quality in the design of the connected piping system and related structures such as expansion joints. Efficiency, and therefore profitability suffer, leading ulti-
Finite Element Analysis For detailed analysis of piping components such as expansion joints, tube sheets, nozzle connections, 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 frequencies and heat transfer calculations.
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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 experience 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 outside 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 experience, training, proprietary techniques, and specialized software, PAI has the capability to solve problems. For more information about Piping Analysis Inc. please visit their website at www.paiengineering.com
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tremendous growth in its business and now solves complex engineering problems all over the world.
Other Engineering Services In addition to failure analysis, PAI offers plant design; including civil and structural analysis, construction drawings, design review, project scheduling, and construction follow up. Global Piping Analysis As a global company with manufacturing facilities around the world, EJS strives to offer many value-added services to complement our products. 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
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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 completely enclosed the leaking fabric expansion 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
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 fabric expansion joint installed in the flue gas inlet duct to the flue gas cooler. The catch was the repair had to be completed while the refinery was in operation. The flue gas line was a 90” (228.6cm) diameter refractory lined duct with
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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.
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For 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 manufacturers. 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 manufacturing 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
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Each product carries the EJS label and all responsibility for the final product including warranty remains with EJS-US. Although each international office is entirely its own entity (incorporated 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 international 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 manufacturer is ASME certified. EJS provides project engi-
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 satisfaction. EJS-US continues to retain all design, engineering, and responsibility for our international offices while providing the more specialized components of the expansion joint assembly directly from our U.S. manufacturing facility. Complex and special bellows are always supplied for final fabrication by EJS-US as well as other complex structures when required.
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neers and quality control staff to each facility for every project that is fabricated providing a smooth completion of the project to EJS standards and ensuring our customers complete satisfaction. 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, complex 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
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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 fabricator specializing in FCCU equipment, refractory, pressure vessels, and many other related structures. Our sales and engineering office for EJS Canada is located in Ontario. This facility provides 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 manufacturing in Kuala Lumpur, Malaysia. Our EJSAP manufacturing partner has several facilities throughout Southeast Asia and provides quality
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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,
products and services for their customers in the oil, gas, petrochemical, and power generation 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 manufacturer 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.
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 manufacturer of process equipment: reactors, heat exchangers, columns, air coolers, and large pressure 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
Yugoslavia and the United Kingdom. These direct offices located throughout Europe, provide an excellent channel to EJS-US.
EJS Europe (EJSEU) Our main European office in Florence,
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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.
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Expansion Joint Systems is represented worldwide by experienced and qualified sales and engineering specialists who will be pleased to offer assistance on the selection and application of any EJS products
Customers Worldwide 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
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] [email protected] Canada - Telephone: (519) 822-1301 • Fax: (519) 822-1128 • E-mail:
[email protected] United States - Telephone: (619) 562-6083 • Fax: (619) 562-0636 • E-mail:
[email protected] • Website: www.ejsus.com
