15.
EXPANSION JOINTS
15.1 INTRODUCTION
Differential longitudinal expansion between the shell and the tube bundle
is a well known problem in fixed tubesheet heat exchanger design. The
differential expansion occurs from two sources: (a) temperature; and (b)
pressure. Temperature induced differential growth warrants no further
explanation. Its presence is directly related to the raison d' etre of the ex-
changer. The effect of pressure induced differential growth, often
overlooked in practical design work in fixed tubesheet exchangers, has been
analyzed in Chapter 9. In physical terms, the mismatch in the axial
deformation of the shell and tube bundle is caused by the difference in the
state of their pressure loadings. The shell is under an internal pressure Ps'
whereas the tubes are subject to a net external pressure of (Ps -PI). In
simple terms, if Ps >PI' then the Poisson effect will cause the shell to shrink,
and the tubes to expand, resulting in a net differential expansion. A more
complete accounting of the pressure induced differential expansion requires
consideration of axial forces in the tubes and in the shell, consideration of
the deflection profile of the tubesheet, etc. Such a complete analysis has
been presented in Chapter 9, where a method for incorporating the presence
of an expansion joint is also described. In the scheme of the overall stress
analysis, the only quantity required to characterize the behavior of the
expansion joint is its "spring rate," defined as the axial pull per unit cir-
cumference of the shell divided by the axial spread of the j9int and has the
units of force per square linear dimension (e.g., pounds per square inch).
The mechanical design of the heat exchanger should, however, not be
confined to the evaluation of spring rate alone. The expansion joint forms
the pressure boundary, sometimes the most vulnerable one, in a heat ex-
changer. Its fragility arises from the fact that it must be made "flexible" to
alleviate differential expansion induced stresses. It is difficult to build-in
flexibility and ruggedness in the same component. Indeed, the first question
in the selection of the expansion joint centers around the" question of the
optimum blend of flexibility, ruggedness, and economy required in the
actual application. At present, the governing safety codes provide little
guidance in the matter. The ASME Code tackles the issue in Code Case
1177-7 which states that the requirements of U-2 (g) of Section VIII of the
Boiler and Pressure Vessel Code be satisfied. In this manner the Code
recognizes the use of any rational stress analysis of expansion joints. The
above referenced Code case also recognizes that expansion joints cannot
normally be designed such that the combination of direct, local membrane
689
K. P. Singh et al., Mechanical Design of Heat Exchangers
© Springer-Verlag Berlin Heidelberg 1984
690 Mechanical Design of Heat Exchangers
and secondary bending stresses is below the Code tabulated allowable
stress. An ASME working group [15.1.1] is presently developing a set of
design rules for expansion joints.
Over the years, many practical forms of heat exchanger expansion joints
have been developed. A brief description of the available types is presented
in the next section. Methods to compute the spring rate and the stress field
in the expansion joint, with appropriate reference to prior work and current
design practice, are given in subsequent sections. An overview of some
practical methods for evaluating the cycle life of expansion joints is also
presented.
Although the foregoing introduction is entirely focused on fixed
tubesheet exchangers, this is not to imply that expansion joints are ex-
clusively used in fixed tubesheet designs. In single pass floating heat ex-
changers, the expansion joint is located in the pipe between the floating
head cover and the shell cover to enable differential thermal expansion
between the tube bundle and the shell. Expansion joints are also widely
utilized in piping runs to alleviate thermal expansion stresses.
15.2 TYPES OF EXPANSION JOINTS
Expansion joints may be broadly classified in two categories; (i) formed
head; and (ii) formed membrane. A brief description of each style follows.
(I) Formed head: This type is made by welding together two specially
formed heads. Figure 15.2.1 shows two "flanged and flued heads" welded
together. A "flanged and flued head" consists of: (a) an outer shell; (b) two
outer tori (flange); (c) two annular plates; (d) two inner tori (flue); and (e)
two inner shells with butt weld to the two portions of the heat exchanger
shell. The inner and outer tori serve to mitigate the severity of geometric
discontinuities between plate and shell type members. The annular plate
contributes significantly to lowering the spring rate. The radii of the tori are
seldom made less than three times the expansion joint thickness. The
thickness of the expansion joint is governed by the pressure and tem-
perature loadings. Since the AS ME Codes do not give formulas for sizing
expansion joint thickness, empirical design practice in the industry com-
monly sets the flanged and flued expansion joint thickness equal to (or one
"gage" less than) the shell thickness. Thus, this type of expansion joint is
quite rugged and not very flexible. The joint is also quite economical to
fabricate. Where the flexibility requirement is rather feeble, further
economy can be realized by eliminating the annular plate (and the outer
cylindrical shell resulting in the semi-torus construction (Fig. 15.2.2).
Another variation is the so-called "flanged only" joint produced by
eliminating the inner torus. Figure 15.2.3 shows three variations. In type
(a), the corner weld between the expansion joint and the inner shell can be
radiographed with some difficulty. The weld in the second style wherein the
annular plate shell is extended cannot be radiographed or volumetrically
examined at all. The same holds true for type c. The shell extension also
