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Metal bellow expansion joint is a flexible element. Element corrugated structure makes expansion joint flexible enough to accommodate linear, lateral, angular, and torsional movements. Bellows are normally used in the piping layout of processing industries, petroleum refineries, thermal power plants, and others to absorb shock, vibration, and thermal movements. Bellow’s design is complex due to the variety of variables involved. The selection of such variables creates major impact on the bellow’s performance and quality. A bellows failure case study was discussed and the failure, failure causes were understood and an enhanced design through optimization was proposed. Visual examination was carried out to check the failure spot as well the conditions of the failed bellows. A plant survey was also performed to review the process as well as the impact of the processing parameters on the piping layout and equipment. From the collected details a failed bellows design was checked as per EJMA calculations. A design was also rechecked with the company standard design software. A metal bellows cannot perform its functions under the low frequency and high amplitude vibration conditions. To ensure the resonant condition of the working unit a vibration measurement was performed. In most of the cases, bellows failed through corrosion. As per the survey and case studies the causes of the corrosion are different and conditions are also different. So to evaluate a design for such conditions needs to be robust. A robust design is less sensitive to noise factors and performs its intended functions. Taguchi methods in general emphasize the robustness of the design. A 5 × 5 design matrix was selected for the optimization. Three sets of design experiments were performed with the standard design calculation code prepared in Excel software as per EJMA standards. Parametric analysis was carried out as per the outcomes from design of experiments and an optimum design to enhance the life cycle and quality of metal bellows expansion joints was proposed.

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Failure Investigation and Parametric Optimization of U-shape Metal Bellow Expansion Joint

  • 会议论文

  • 发表日期：

    2026年

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  • Vijay Parekh,
  • Anish Gandhi

摘要

Metal bellow expansion joint is a flexible element. Element corrugated structure makes expansion joint flexible enough to accommodate linear, lateral, angular, and torsional movements. Bellows are normally used in the piping layout of processing industries, petroleum refineries, thermal power plants, and others to absorb shock, vibration, and thermal movements. Bellow’s design is complex due to the variety of variables involved. The selection of such variables creates major impact on the bellow’s performance and quality. A bellows failure case study was discussed and the failure, failure causes were understood and an enhanced design through optimization was proposed. Visual examination was carried out to check the failure spot as well the conditions of the failed bellows. A plant survey was also performed to review the process as well as the impact of the processing parameters on the piping layout and equipment. From the collected details a failed bellows design was checked as per EJMA calculations. A design was also rechecked with the company standard design software. A metal bellows cannot perform its functions under the low frequency and high amplitude vibration conditions. To ensure the resonant condition of the working unit a vibration measurement was performed. In most of the cases, bellows failed through corrosion. As per the survey and case studies the causes of the corrosion are different and conditions are also different. So to evaluate a design for such conditions needs to be robust. A robust design is less sensitive to noise factors and performs its intended functions. Taguchi methods in general emphasize the robustness of the design. A 5 × 5 design matrix was selected for the optimization. Three sets of design experiments were performed with the standard design calculation code prepared in Excel software as per EJMA standards. Parametric analysis was carried out as per the outcomes from design of experiments and an optimum design to enhance the life cycle and quality of metal bellows expansion joints was proposed.