EXPANSION JOINTS FOR FLUID CATALYTIC

CRACKING UNITS

Our experience, your benefit

Belman has extensive experience in the design and manufacture of Expansion Joints for Fluid Catalytic Cracking Units (FCCU) and has a correspondingly impressive reference list, selected examples of which are featured in this brochure. A full reference list can be forwarded on request.

Expansion Joints in FCC units The Expansion Joints utilised in this application are the most technically advanced among all the existing types, as they are exposed to: Highly aggressive and abrasive

media Extremely high temperatures Large movements

The FCCU Expansion Joints are placed around the reactor and carry mainly spent regenerated, recirculation catalyst and flue gas.

Why Belman?Since its foundation in 1994 Belman has established itself as a leading designer and manufacturer of highly engineered and customised Expansion Joint solutions for critical applications. This includes the nuclear power industry, oil platforms, LNG/LPG sector, steel industry, heat exchangers, power plants and of course oil refineries.

After years of supplying highly customised expansion joint solutions for the oil refineries, they started to request assistance for FCCU Expansion Joints as well.During the last decade Belman has enhanced its reputation as an experi-enced and innovative designer and manufacturer of high-end Expansion Joints and also high-end FCCU Expansion Joints.

BELMAN & EXPANSION JOINTS FOR FLUID CATALYTIC CRACKING

PRODUCT RANGE

FCCU Expansion Joints designed and manufactured by Belman are typically within our general Expansion Joint range, which is:• Dimension: DN 15-6000

(up to DN 12.000 in segments) • Bellows: Rolled, punch- and

hydraulic formed bellows• Design pressure: Up to 150 barG

(depending on the diameter and temperature)

• Lifting capacity: Up to 40 tonnes

BELMAN IS REKNOWNED FOR:

• High-end Expansion Joints• On time delivery • Documentation• Cost-efficient customised

Expansion Joint Solutions• High level of experince,

guidance• High level of information

exchange • Advanced analysis, calcula-

tions and engineering• Flexibility

FCC (Fluid Catalytic Cracking Units) - CIS

8,1 METER LONG EXPANSION JOINTDN 1100, PN: 3,92 BarG, Design temperature: -40/+552ºC

Belman is experienced in working with complex specifications and preparing highly advanced technical Expansion Joint solutions. Belman designs and manufactures FCCU Expansion Joints according to customer requests and needs. As part of our service we provide: • 3D parametric design and

modelling• Finite Element Analysis (FEA) • Pipe stress analysis of the

complete pipe system with the FCCU Expansion Joint

• Pipeline engineering (Rohr2)• Pipeline and part simulation

(Rohr2)• and much more

In the engineering phase we design the solution to meet the specified require-ments and the challenges of the project such as maximum stresses on the nozzles, limited space, issues with pipe support systems etc.

SpecificationsBelman is experienced in working with the various specifications demanded by clients, different FCC Technology Providers and licensors engaged in the global refining industry such as Axens, KBR, Shell, ExxonMobil, UOP and many more. We also advise clients concerning design enhancements in order to improve the originally specified solution.

ADVANCED ENGINEERING & DESIGN

Belman provides you:• Competitive quotations• All details on the design in an early

stage incl. specifications and drawings on the Expansion Joint/-s.

• Fast quotation process• Full support and advice on

solutions and issues• Piping engineering such as

pipeline versus Expansion Joint

Design codesBelman is experienced with many different design codes and among others design FCC according to:• ASME VIII• ASME B31.3• EJMA • EN 13445• EN 14917• EN 13480• AD 2000

Belman Expansion Joints for Fluid Catalytic Cracking Units are always designed according to client specifica-tions and requests and of course are based on the selected standards or specifications from clients. Generally speaking Belman Expansion Joints for FCC can be divided into 3 main categories:

Cold wall These Expansion Joints are designed with a refractory lining to ensure the outside wall temperature will not exceed the maximum. The wall is made from ordinary steel types. The lining is placed on the inside of the Expansion Joint. Due to the critical application very few companies possess the required know-how to carry out refractory work and Belman cooperates only with the most qualified and experienced

providers. In addition only a few raw materials for the refractory are approved for this critical purpose. This makes us very selective in both the choice of cooperative partners/sub suppliers and materials.

Hot wall These 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. UnlinedThese Expansion Joints are designed in

TYPES & DESIGN

take up the load and operate until the next shutdown.

MonitoringAn 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 monitoringThis solution gives good monitoring options as well as increasing opera-tional safety. 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 under 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:• Passive monitor

If the inner ply fails the monitor is activated by the increasing pressure between the plies. This monitor will only indicate the failure in an 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 on both the inner and the outer ply.

BELLOW CONSTRUCTION & LEAK MONITORING

The critical operating conditions create challenging requirements in regards to the design of the FCCU Expansion Joints. The Expansion Joint is a key component in the pipe system and the careful selection of bellow material is important. The selection of the most suitable material is often done accord-ing to customer requirements, the specification and/or based on experi-ence.

Bellows formingThe 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. Simple double ply bellows utilises the strength of both plies to withstand the operation 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 is leaking the outer ply will be able to

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) is placed on top with the addition of a wall/cover. Although these Expansion Joints are also exposed to the very high tempera-tures, 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 gasses from the reactor. With the exception of a 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.

REFRACTORY LINING

Refractory lining is an important element of FCC Expansion Joints and FCC 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 work with the best companies within refractory lining to ensure high quality, suitable linings for the application. Thereby ensuring the smooth operation without any costly

unexpected shutdown. Belman meets the refractory lining specifications from licensors specifications in the same way as for the design of the complete unit.

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

Installation of refractory liningThe insulation and the refractory lining is

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 hexmesh etc. We work only with best in class refractory lining companies that have the same levels of quality control and knowhow as Belman.

Only the best...

Belman works only with the best, high end brands concerning refractory lining. The partners selected for refractory lining are located very close to Belman.

CUSTOMISED EXTERNAL HARDWAREDifferent types of external hardware are used to perform various functions on FCCU units. These are:

Man holeTo ease inspection of the inside of the pipeline. Belman can design and produce Expansion Joints with man holes. Both standard man holes or a customised man hole, like that illustrated, with refractory inside and a removable cover to save space and simplify transportation. As the man hole cover is very heavy, due

mainly to the refractory lining, a smart opening and closing mecha-nism on the man hole was made – making the task of lifting and opening convenient and simple. Belman always designs according to the requirement and needs of the client.

Bellow protecting coversThese 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 linkagesThese are used to equalise the movements between the bellows. Whereas the hinges absorbs the main load. Pantographic linkages are not designed to restrain pressure thrust.

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

Control rodsControl 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 nozzlesThey 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 hingesThey ensure that each bellows absorbs the same axial movement, however only in Universal Expansion Joints. In situations when the FCCU Expansion Joints are installed horizontally, hinges support the weight of connecting pipe of the two bellows (including medium weight and refractory lining).

FCC (Fluid Catalytic Cracking) - CIS

5,7 METER LONG EXPANSION JOINTDN 1100, PN: 3,92 BarG, Design temperature: -38/+650ºC

The FCCU Expansion Joints are manufactured, tested and inspected in our state-of-the-art production. Belman is known for its efficient, well-organised, innovative and clean production.

Belman is focused on quality assurance, this also includes welding. Within this area, we follow both client requests, project requests, our own procedures, our own quality objec-tives and the requirements of the design codes.

Welding and welding inspectionA natural step for Belman has been to control the welding process tightly to ensure that we have the right quali-

fied welding procedure (WPS) for the project and also that we are using the right certified welders for the project. We hold a database with more than 200 different qualified WPS.

All welding activity is carefully inspected under supervision of our own inspectors (IWS and IWIS).We have 100% traceability on all ma-terials, we also have full traceability on all filler materials. 3.1 certificates can be provided for all of them.

All documentation is kept in our files for a minimum of 10 years, which means we can always find the required documentation for the client should they need it.

PRODUCTION & WELDING

Belman’s focus on the quality of welds

and innovation means that robotic

welding techniques are also incorpo-

rated in our production of expansion

joints.

ADVANCED WELDING

Quality assuranceWe are often involved in projects where Expansion Joints form part of a critical application, therefore we understand the importance of the supporting documentation. A detailed quotation, supporting calculations, extensive quality control and testing procedures will generally be a part of the project documentation. This also includes a study of provided specifications, close dialogue with the customer, inspection of welding consumables, materials and a sub-supplies audit, test, documenta-tion and final inspection.

Documentation Full traceability and welding documentation. Among others:

WPS WPQR PQR NDT

All orders are accompanied by a complete package of documentation should the customer request.

ITP plan & testsBelman always provide ITP. In addition to a standard visual inspection, upon agreement Belman can undertake additional quality tests such as: Positive material identification (PMI), radiograph-ic examination, dye penetrant, magnetic particle examination, hardness testing, ultra sound, pressure testing and leak detection.

QUALITY ASSURANCE & TEST

To minimise the risk of an unplanned shutdown and ensure smooth operation many clients make use of Belman’s experienced and qualified on-site service team to perform the installation or to supervise it.

In the event of an unexpected leakage or the repair of the Expansion Joint being required earlier than planned, Belman’s on-site service team can assist. This could be through the installation of a Clamshell Bellow or undertaking the replacement if a short shutdown is possible.

ADDITIONAL SERVICES ON-SITE SERVICES

Belman on-site servicesBelman’s on-site service team expertly assist clients with:• Full installation• Repair/refurbishment of FCCU

Expansion Joints• Replacement of FCCU

Expansion Joints • Supervision of installation,

assembly etc.• Problem troubleshooting• Installation of Clamshell Bellows

REFERENCES

Belman have successfully assisted clients like BP, Shell, TOR and many others with on-site services at their refineries.

An on-site service reference list can be forwarded on request.

FCC (Fluid Catalytic Cracking) - Tatarstan

30 TONNE EXPANSION JOINTDN 1250, PN: 4,6 BarG, Design temperature: +350ºC

CASE STORY

CUSTOMISED 30 TONNE FCC EXPANSION JOINT

This customized Expansion Joint was designed, manufactured and tested for a fluid catalytic unit located in an oil refinery complex. It is installed in the pipe bend above the reactor and at an approximate height of 100 meters. 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. Customized FCCU Expansion JointTraditionally, most FCC Expansion Joint designs are made strictly according to standards and client specified design codes. For this 30 tonne Expansion Joint the client specially requested that the inside should be easy to access. For that reason, a man hole on the FCC Expansion Joint was made in order to facilitate easy access and inspection of the unit during mainte-nance. This man hole was custom-made with a removable cover to save space and simplify transportation. As the man hole cover is very heavy, due mainly to the refractory lining, a smart opening and closing mechanism on the man hole was made making the task of lifting and opening convenient and simple. A customised approach in regards to the bellows inner soft insulation was required due to the high

risk of damage to the bellows “packing” by aggressive and abrasive media.Typically, FCC Expansion Joints are equipped with one metallic cable acting as an extra sealing for the inner ceramic wool insulation. This prevents small particles from entering and settling in the bellow. The customer was con-cerned that the large lateral movements would shift the cable from its original position and thereby generate a gap through which the media could penetrate and damage the bellow. In order to solve this a double cable solution was chosen. In this way the second cable is placed slightly lower on the inner sleeve opening, thereby sealing any potential gap which might occur during the lateral displacement of the unit. AXENS & ASMEThe Expansion Joint is calculated according to Axens standards and furthermore ASME. Belman has vast experience in the design of expansion Joints according to different standards and design codes. Due to this substan-tial experience Belman can easily customise the design and production to any required design code and/or standard.

2-ply testable bellows & leak detectionLeak monitoring was also specified amongst the requirements. For that reason, pressure gauge devices are installed at the Expansion Joint to indicate any issues with the bellows during operation. Further, the Expansion Joints are specified with “packed” bellows designed as 2 ply testable bellows with redundant construction. With this construction the single layer would be able to carry the full load in the event of operating alone. In other words, if one of the layers fails, the other ply would be able to secure operational safety of the Expansion Joint until a scheduled shutdown.

Design parameters of the FCC Expansion JointThe FCC Expansion Joint have the following design parameters:Quantity: 1 pcs • Dimension: DN 1250 • Length: 10000 mm • Medium: Flue gas • Lining: Resco • Design tempera-ture: 350°C • Design pressure: 4,6 barG • AX: +0/-70 mm • LA: +/-150 mm • AN: +/-0,5° • Bellows: 2.4856 (Inconel 625 (LCF)) • Welding ends, middle pipe: SA-516 gr. 70

CASE STORY

DELIVERY TIME REDUCED TO 12 WEEKS

Belman designed and manufactured 3 refractory lined FCC Expansion Joints for an oil refinery in the CIS. The Expansion Joints are placed around the reactor and carry mainly spent, regenerated, recirculation catalyst and flue gas. A short delivery time was essential for this project and Belman produced all units in only 12 weeks. The exceptionally rapid delivery was made without compromising on quality, documentation and project require-ments.

Belman was involved at the design stage The project concerned the moderniza-tion of an old FCC unit. However, Belman started the project from the scratch based on drawings of the current system. The client requested Belman to find a suitable method to relieve the stresses on the nozzles. The solution was found in close cooperation with the client and based on Axens specifications. This was further combined with Belman’s experience and UOP’s practices. This means the same approach as UOP by offering 2

ply bellows, where one layer is able to carry the full load. On the basis of ourtechnical proposal the client issued the project specification. Belman made Finite Element Analysis (FEA), bellow and part calculations and analysis of the stresses in the pipeline and the resultant loads on vessel nozzles.

Critical design parametersOne of the Expansion Joints was refractory lined due to the high tempera-ture. The other two units were designed with soft insulation on the bellow. Heavy stresses on the bellows caused by high pressure, temperature and large movements make this part vulnerable and for this reason bellows were made from Inconel 625 LCF. The Expansion Joints bellows were manufactured by punch forming.

Two-ply testable bellowsThe design criteria required that the two-ply bellows had to be calculated so that the single layer is able to bear the full load if the inner layer failed. The outer ply is then able to secure

operational safety until a scheduled shutdown. Furthermore, the Expansion Joints were fitted with a pressure gauge to indicate any possible failure of the inner ply of the bellow.

Design parametersThe FCCU Expansion Joints has various design and have the following design parameters:

Dimension: DN 1100 • Installation length: 8818 mm • Design pressure: 3,92 barg • Design temperature: 552°C • AX: +0/-80 mm • LA: +/-350 mm • AN: +/-0,5° • Bellow: 2.4856 • Welding ends: SA-516 gr. 70 • Intermediate pipe: 1.0425

Dimension: DN 1100 • Installation length: 5606 mm • Design pressure: 3,92 barg • Design temperature: 552°C AX: +0/-80 mm • LA: +0/-50,4 mm • Bellow: 2.4856

Dimension: DN 1100 • Installation length: 5691 mm • Design pressure: 3,92 barg • Design temperature: 650°C AN: +0/-4° • Bellow: 2.4856

EXCELLENCE IN FCCU

SELECTED REFERENCES

FCC (Fluid Catalytic Cracking) - Russia

PANTOGRAPHIC GIMBALDN 900, PN: 7,6 BarG, Design temperature: -30/+538ºC

FCC (Fluid Catalytic Cracking) - Tatarstan

REFRACTORY LINEDDN 1000, PN: 4,6 BarG, Design temperature: 350ºC

FCC (Fluid Catalytic Cracking) - Russia

10,4 METER LONG EXPANSION JOINTDN 1332, PN: 3,87 BarG, Design temperature:-30/538ºC

FCC (Fluid Catalytic Cracking) - Russia

REFRACTORY LINEDDN 900, PN: 3,92 BarG, Design temperature: -30/538ºC

FCC (Fluid Catalytic Cracking) - Tatarstan

COMPACT EXPANSION JOINTDN 900, PN: 4,6 BarG, Design temperature: 350ºC

REFERENCES FOR OIL REFINERIES WORLDWIDE

Through the years Belman has successfully supplied both simple Expansion Joints, customised Expan-sion Joints, complex Expansion joints designs and FCCU Expansion Joints to:

Total Fina Elf • BP • Gunvor Petroleum (Prev. Kuwait Petroleum Europoort B.v (Q8)) • Shell • Equinor (Statoil) • Rosneft • Enap • TOR • MOL • Chevron • Eni • Qapco • Murco Petroleum Limited • Linde Ag • Lukoil • Preem • PKN Orlen •Saudi Aramco • Total (Maersk Oil) •Ceylon Petroleum • OMV • Tatneft •Termo Petroleo • Repsol

For many of these companies Belman has supplied several times and to several of their global entities.

A full experience list highlighting our references can be forwarded on request.

Did you know that... Belman supply

Exhaust Expansion Joints

For several decades Belman has succesfully supplied Exhaust Expansion Joints for installation onboard all types of vessels.

Read more here: www.belman.com/ exhaust-expansion-joints

Did you know that...

Belman is experienced in working with EPC companies for FCCU

Expansion Joints

D E S I G N

A S S E S S E D

Belman A/S | Denmark | T: (+45) 7515 5999 | belman@belman.com | www.belman.com

Belman-UK Limited | United Kingdom | T: (+44) (0) 161 491 5515 | sales.uk@belman.com | www.belman.com

OOO Belman Russia | Russia | T: (+7) (812) 445 2195 | info@belmanrussia.ru | www.belmanrussia.ru

BELMAN GROUP

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Our experience, your benefit

For more information about our sales and production entities as well as our cooperative partners please refer to our website or contact us.

Belman A/S | Denmark | T: (+45) 7515 5999 | belman@belman.com | www.belman.com

Belman-UK Limited | United Kingdom | T: (+44) (0) 161 491 5515 | sales.uk@belman.com | www.belman.com

OOO Belman Russia | Russia | T: (+7) (812) 445 2195 | info@belmanrussia.ru | www.belmanrussia.ru

BELMAN GROUP

For more information about our sales and production entities as well as our cooperative partners please refer to our website or contact us.

Belman Partnerin Austria:

RKG Energietechnik GmbHMurlingengasse 421120 WienÖsterreich

T: +43 1 813 35 16E: office@rkg.at