BEST-IN-CLASS

FCCU EXPANSION JOINTS

Expansion Joints installed in Fluid Catalytic Cracking Units (FCCU) are exposed to very demanding operating parameters such as:

Highly aggressive and abrasive media
Extremely high temperatures
High pressure
Large movements

The FCCU Expansion Joints must be resistant to those operating parameters and at the same time flexible enough to absorb movements as well as ensure safe and smooth operation. Consequently, the FCCU Joints utilised in this application are considered highly engineered units and are among the most technically advanced of all existing Expansion Joint types. Therefore, it is essential that each Expansion Joint assembly is correctly and specifically engineered to the application.

During the last decades, Belman has enhanced its reputation as an experienced and innovative designer and manufacturer of high-end Expansion Joints, including high-end FCCU Expansion Joints. The design and manufacturing of FCCU Expansion Joints requires great expertise and capabilities. Only a handful of manufacturers worldwide have the expertise to produce high-tech FCCU Expansion Joints of this kind, and being highly specialised in high-end customised solutions Belman has joined this exclusive group. All Expansion Joints manufactured by Beman for FCC service are designed according to recognised codes, including the standards of the Expansion Joint Manufacturers Association (EMJA).

Design range and scope of supply within FCCU Expansion Joints

FCCU Expansion Joints designed and manufactured by Belman are abrasion-resistant refractory-lined and unlined Expansion Joints for fluid catalytic cracking. The FCCU Expansion Joints are typically ranging up to DN 1800, 27 metric tonnes in weight and up to 13.5 metres in length. The design capabilities for Belman FCCU Expansion Joints are:

DIMENSIONS:
DN 15-12,000

PRESSURE:
Up to 150 Barg / 2176 psi

TEMPERATURE:
-165°C to +1000°C

MATERIALS:

Austenitic stainless steels, High alloys, Duplex, Titanium, Hastelloy, Incoloy, Inconel, Alloy 59

DESIGN CODES:

EN 13445, EN 13480, EN 14917
ASME VIII, div.I, ASME B31.3
ASME B31.1, EJMA, AD 2000
and others on request

TESTS:

Radiographic examination (X-ray), Helium leak testing, Pressure test, Air test, Dye penetrant test, Magnetic particle examination and many more

ENGINEERED

FCCU EXPANSION JOINTS

Pipe Expansion Bellows for Fluid Catalytic Cracking Units (FCCU)

FCCU EXPANSION JOINT PROJECTS

CASE STORIES

Engineered and highly customised FCCU expansion joint

FCC DELIVERED IN ONLY 12 WEEKS

As delivery time was essential for the client, Belman responded by producing 3 FCC Expansion Joints in an exceptionally short delivery time of 12 weeks.

30 TONNE FCC EXPANSION JOINT

This FCC Expansion Joint weighs in at 30 tonnes due to the conditions requiring a large Expansion Joint, both in terms of length and dimension.

Fluid catalytic cracking expansion bellows as per KBR specifications and ASME B31.3:2010

SPECIAL FCCU DESIGN

Highly engineered FCCU Expansion Joints for an oil refinery in Spain designed according to KBR specifications and the ASME B31.3:2010 design code.

EXPERIENCED & APPROVED SUPPLIER

REFERENCES

OIL & GAS

Total Fina Elf • BP • OMV • Gunvor Petroleum (Prev. Kuwait Petroleum
Europoort B.v (Q8)) • Shell • Statoil • Rosneft • Enap • TOR • MOL • Chevron • Eni • Murco Petroleum Limited • Linde Ag • Qapco • Lukoil • Preem • Total • PKN Orlen • Saudi Aramco • KNPZ • Maersk Oil • Tatneft • Cepsa • Idemitsu • Sobegi • PCK • PLAINS • Aker BP •

Ceylon Petroluem • Termo Petroleo • Repsol • Equinor (Statoil) • Novatek • Valero • PETKiM • China National Petroleum Corporation (CNPC) • Ineos • National Refinery • Valero • GE Oil & Gas • ExxonMobil • Sinopec • Petrogal • NOV • Ruhr Oel • Rosenberg (Worley) • ST1 • SOCAR • Sonatrach • Lukoil Neftochim Burgas • PETRONAS •

See more references

FCCU EXPANSION JOINTS

TECHNICAL DESCRIPTION

TYPES & DESIGN

Belman Expansion Joints for Fluid Catalytic Cracking Units are always designed according to client specifications and requests, and of course are based on the selected standards or specifications selected by the client. Generally speaking, Belman Expansion Joints for FCC can be divided into 3 main categories: cold wall designs, hot wall designs and unlined designs. The choice between them depends on the client’s request, the medium, the temperature and the operation and shutdown conditions the Flexible Joint will be exposed to over its lifetime.

Cold wall FCCU

The cold wall Expansion Joints are designed with a refractory lining to ensure the outside wall temperature will not exceed the maximum design temperature. Because the internal insulation keeps the shell cool, the wall can be made from ordinary steel types. The lining is placed on the inside of the Expansion Joint, and typically consists of an internal insulating refractory lining held in place by an anchoring system. Due to the critical application, very few companies possess the required know-how to carry out refractory work, and Belman cooperates only with highly qualified and experienced providers. In addition, only a few raw materials for the refractory are approved for critical cold wall compensators. This makes us very selective in both the choice of cooperative partners/subsuppliers and materials for cold wall Expansion Joints.

Hot wall FCCU

The hot wall Expansion Joins are designed with the refractory lining on the inside as a thermal barrier. This predisposes an abrasion resistant lining, consisting of hex mesh and castable refractory materials. The purpose of this lining is to withstand abrasion from the catalyst flow medium, but thermal impact due to high temperatures normally requires the wall to be made from high-temperature stainless or carbon steels.

Unlined FCCU

The unlined Expansion Joints are designed in the same format as the hot wall Expansion Joints but without the hex mesh and refractory lining. The wall is made from high-temperature steels in order to resist the abrasive media and corrosion. Soft insulation materials (typically ceramic wool) are placed on top with the addition of a wall/cover. Although these Expansion Joints are also exposed to very high temperatures, they do not carry catalyst in the media, and this type is insulated on the outside with ceramic wool with steel covers mounted on top. Normally, these are installed in the air inlet/outlet or in the transfer of gases from the reactor. With the exception of the lining, the unlined Expansion Joints are very similar to the other types, as they operate under very similar severe working conditions. The shell is often made from highly alloyed materials.

Engineering at Belman

3D illustration of a FCC expansion joint

BELLOWS CONSTRUCTION
& LEAK MONITORING

The critical operating conditions create challenging requirements with regard to the design of the FCCU Expansion Joints. The Expansion Joint is a key component in the pipe system and the careful selection of Bellows material is important. The Bellows element is the part that absorbs the movements. The selection of the most suitable material is often done according to customer requirements, the specification and/or based on experience.

Bellows forming

The Bellows are normally formed either by punching or hydraulic forming.

2-ply testable Bellows

Double ply or redundant ply bellows are widely used for FCCU applications, because they improve reliability. Simple double ply Bellows utilise the strength of both plies to withstand the operating conditions. Redundant ply Bellows are designed in such a way that each ply will be able to take up the full load. So if the inner ply leaks, the outer ply will be able to take up the load and operate until the next shutdown. This prevents an unscheduled shutdown and allows the repair to be planned.

Monitoring

An option is to use control rods which monitor the complete system. The control rods are mounted over the bellows and monitor the movements. If the insulation is worn out, the heat will increase, and this higher temperature will result in larger movements.

Leak monitoring

This solution gives good monitoring options as well as increasing operational safety. Belman offers either active or passive monitoring, depending on the level of safety required. The two-ply design is monitored through a leak indicator (pressure gauge monitor). A redundant ply design offers even better safety and monitoring options, as the unit stays in operation until the scheduled outage even in the event of a minor leakage. Redundant ply bellows are calculated in a way that the single layer would be able to carry the full load alone. In other words, if the inner layer fails, the outer ply would be able to secure operational safety of the Expansion Joint until a scheduled shutdown. Additionally, the Expansion Joints are fitted with a pressure gauge monitor indicating the failure of the inner ply.

Generally speaking, there are two types of monitors that can be used as an early warning system:

Passive monitor
If the inner ply fails, the monitor is activated by the increasing pressure between the plies. This monitor will only indicate a failure in of the inner ply.
Active monitor
A vacuum is created between the inner and the outer ply before installing this monitor. If the inner ply fails, the pressure between the plies will activate the monitor. If the outer ply fails, the monitor is activated by the loss of vacuum. This monitor can detect failures of both the inner and the outer ply.

REFRACTORY LiNING

Refractory lining is an important element of FCCU Expansion Joints and FCCU components. Belman can arrange for the refractory lining and thereby deliver the complete FCCU Expansion Joint. However, should the client prefer, they can arrange for the refractory lining themselves. Belman works with specialised companies within refractory lining to ensure high quality, suitable linings for the application. This ensures the smooth operation without any costly unexpected shutdown. Belman meets the licensors’ refractory lining specifications in the same way as for the design of the complete unit. Because all these critical linings are exposed to both abrasion and thermal expansion, correct material choice, installation and dry-out are essential for a greatly improved service life.

Refractory materials

Belman always selects the refractory lining specified and/or requested by the client, such as eg. Resco.

Installation of refractory lining

The insulation and the refractory lining are provided in accordance with the specifications and agreements with the client. Belman can install by casting, gunning (pneumatic application), hand-placing or pneumatic ramming. Belman is experienced with the provision of anchoring systems such as hex mesh etc. We work only with best-in-class refractory lining companies that have the same levels of quality control and know-how as Belman.

Refractory lined expansion joints for FCC

CUSTOMISED
EXTERNAL HARDWARE

Manhole

To ease inspection of the inside of the pipeline, Belman can design and produce Expansion Joints with manholes. Both standard manholes or a customised manhole, like the one illustrated, with refractory inside and a removable cover to save space and simplify transportation. As the manhole cover is very heavy, due mainly to the refractory lining, a smart opening and closing mechanism has been developed for the manhole – making the task of lifting and opening convenient and simple. Belman always designs according to the requirements and needs of the client.

Bellows protecting covers

These covers are normally specially designed for the FCCU Expansion Joints and are typically made from 2-3 mm thick plate. The covers are normally telescopic in design. With this installation the bellows are very well protected.

Pantographic linkages

These are used to equalise the movements between the Bellows, whereas the hinges absorb the main load. Pantographic linkages are not designed to restrain pressure thrust.

Gimbal pantographs

Units that need to absorb lateral movement in two planes should be equipped with a gimbal pantograph. The centre ring allows the joint to offset in the opposite plane to the pantograph without the linkage binding.

Control rods

Control rods are used to control and limit the movements of the bellows. They are not designed to restrain pressure thrust. In emergency cases, the tie rods can even absorb the loads if needed.

Sampling nozzles

Sampling nozzles are used for various reasons and are specified by the end user. Pipes penetrate the shell wall and can often interfere with other hardware. The nozzles can be placed at different locations according to the client specifications, design requirements and/or the need of the application.

Slotted hinges

Slotted hinges ensure that each bellows absorbs the same axial movement, but only in Universal Expansion Joints. When the FCCU Expansion Joints are installed horizontally, hinges support the weight of the connecting pipe between two Bellows (including medium weight and refractory lining).

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CATALOGUE

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QUALITY & TESTS

Belman is known for high-quality products, and therefore our quality control is a fundamental part of our business. All processes during production designed by the Belman quality engineers, are strictly followed and implemented according to our procedures and instructions and carefully inspected by Belman quality inspectors. All checks and inspections are done according to the strict prevailing Belman quality control procedures, which are part of the Belman ISO 9001 quality management system approved by DNV.

ITP & Test
The Inspection Test Plan generated by the quality management system makes sure that each step of manufacturing has the appropriate inspection points, such as Hold and Witness points.

Based on manufacturing code, project specification, application, media, and eventual ship classification rules Belman performs a large variety of quality tests, including destructive testing, non-destructive testing and proof testing. All tests can be witnessed by a third party based on the customer and classification requirements.

Destructive tests, such as life cycle test and burst test to validate the design, i.e., vessels and offshore platforms
Non-destructive tests, such as Visual testing, dye penetrant test, Radiography examination, Magnetic testing, ultrasonic testing, hardness testing and PMI for all applications
Proof tests, such as leak test with air, leak test with helium and “formier” gas, hydrostatic pressure test for all applications

FCCU EXPANSION JOINTS

INSTALLED

ENGINEERED

EXPANSION JOINTS SINCE 1994

This enables us to find you the optimum FCCU Bellows for your piping system.