APPENDIX 5
FLANGED AND FLUED OR FLANGED ONLY
EXPANSION JOINTS
5-1 GENERAL
5-1(a) Flanged and flued or flanged only expansion
joints used as an integral part of heat exchangers or other
pressure vessels shall be designed to provide flexibility for
thermal expansions and also function as pressure con-
taining elements. The rules in this Appendix are intended
to apply to typical single layer flanged and flued or flanged
only elements shown in Fig. 5-1. They are limited to appli-
cations involving only axial deflections.
The suitability of the expansion joint for the specified
design, pressure, and temperature shall be determined
by methods described in this Appendix.
5-1(b) In all vessels with expansion joints, the hydro-
static end force caused by pressure and /or the joint
spring force shall be contained by adequate restraining
elements (i.e., tube bundle, tubesheets or shell, external
bolting, anchors, etc.). The average primary membrane
stress [see UG-23(c)] in these restraining elements shall
not exceed the maximum allowable stress at the design
temperature for the material given in the tables given
in Subpart 1 of Section II, Part D.
5-1(c) Joint flexible elements shall not be extended,
compressed, rotated, or laterally offset to accommodate
connecting parts which are not properly aligned, unless
such movements have been accounted for in the design
under the provisions of U-2(g).
5-1(d) This Division does not contain rules to cover
all details of design and construction of expansion joints.
The criteria in this Appendix are therefore established to
cover most common forms of flanged and flued or
flanged only expansion joints, but it is not intended
to limit configuration or details to those illustrated or
otherwise described herein. For designs which differ
from the basic concepts of this Appendix (e.g.,
multilayer, asymmetric geometries or loadings, etc.),
the design requirements of U-2(g) apply.
5-2 MATERIALS
Materials for pressure retaining components shall
conform to the requirements of UG-4. For carbon
360.1
A02
and low alloy steels, minimum thickness exclusive of
corrosion allowance shall be 0.125 in. (3.2 mm) for
all pressure containing parts. The minimum thickness
for high alloy steel shall conform to requirements of
UG-16.
5-3 DESIGN
The design of expansion joints shall conform to the
requirements of Part UG and those of (a) through (g)
below.
5-3(a) The design of expansion joint flexible elements
shall satisfy, in both the corroded and noncorroded
condition, the following combinations of maximum
stress components and corresponding stress limits [see
(b) below].
5-3(a)(1) Pressure Loadings Only. The maximum
stress at any location within the joint shall be limited
to 1.5S, except as provided below. The references to
maximum stress do not include any effect of stress
concentrations.
(a) For tubular heat exchangers, considering tube
side pressure, the stresses may be evaluated only in
accordance with provisions of (a)(2) below if the re-
straining elements are not dependent on the stiffness
of the expansion joint in order to satisfy the stress
requirements of 5-1(b).
(b) For tubular heat exchangers, considering
shell side pressure, when the restraining elements are
not dependent on the stiffness of the expansion joint
in order to satisfy the stress requirements of 5-1(b):
(1) the maximum membrane plus bending
stress in the annular plates or straight flanges (see Fig.
5-1) shall be limited to 1.5S;
(2) the maximum membrane stress in the
corners and torus (radius portion of the flange or flue,
see Fig. 5-1) shall be limited to 1.5S;
(3)(a) the maximum membrane plus bending
stress in the corners and torus shall be limited to 1.5S
except as provided in (3)(b) below;
5-3 2001 SECTION VIII — DIVISION 1 5-3

Straight flange (typ.)

Outer torus (typ.)

rb Annular plate (typ.) rb

Corner Inner torus (typ.)

ra

Rb Rb
Ra

(a) Flanged Only (b) Flanged and Flued

GENERAL NOTE: ra , rb ⱖ 3t for Kg ⫽ 1.

Ra , Rb ⫽ inside radius of expansion joint straight flange, in. (mm)

t ⫽ uncorroded thickness of expansion joint straight flange, in. (mm)

FIG. 5-1 TYPICAL FLANGED AND FLUED OR FLANGED ONLY FLEXIBLE ELEMENTS

(3)(b) the maximum membrane plus bending
stress in the corners and torus shall be limited to
SPS [see UG-23(e)], provided it is demonstrated that
rotational stiffness at the corners and torus is not needed
to maintain the maximum stress in the annular plates
or straight flanges equal to or less than 1.5S.
5-3(a)(2) Pressure Plus Axial Deflection (Pressure
or Thermally Induced) Loadings. Considering the most
severe combination of pressure(s) and axial deflection,
the maximum stress (not including any effects of stress
concentration) at any location in the joint shall be
limited to SPS [see UG-23(e)].
5-3(a)(3) Cyclic Pressure and Axial Deflection
(Pressure or Thermally Induced) Loadings. Considering
the most severe combination of pressure(s) and axial
deflection, the maximum stress multiplied by the appro-
priate value of Kg (to include any effect of stress
concentration) at any location within the joint shall be
limited to Sn
where
Sp maximum allowable stress value, psi (MPa) (see
applicable table of allowable stress values in
Subpart 1 of Section II, Part D)
Snp the maximum range of stress allowed for the
required life cycles N of the joint, psi (MPa).
Sn shall be determined by using the appropriate
formula of (c) below.
Kgp fatigue strength reduction factor which accounts
for geometric stress concentration due to local
thickness variations, weld geometry, and other
surface conditions. The value of Kg shall not be
less than 1.0 but need not be greater than 4.0.
The minimum value of Kg will apply for smooth
geometrical shapes, and the maximum value
will apply for 90 deg. welded corners and fillet
welds. Fatigue strength reduction factors may
be determined from theoretical, experimental,
or photoelastic studies. (For flanged and flued
type expansion joints with a knuckle and flue
radius equal to or greater than three times the
corresponding joint thickness at the knuckle and
flue and meeting all the design, fabrication, and
examination requirements of this Appendix, a
Kg of 1.0 may be used. For flanged only expan-
sion joints, a Kg of 4.0 is recommended at the
flexible element-to-shell weld).
5-3(b) The calculation of the individual stress compo-
nents in (a) above and their combination shall be
performed by any method of stress analysis which can
be shown to be applicable to expansion joints.
5-3(c) The required joint design life N in cycles
shall be established by the designer considering the
anticipated number of stress cycles (pressure and /or
deflection) expected to occur during the operating life
of the unit, but in no case shall it be less than 100.
The suitability of an expansion joint to withstand
the required number of cycles shall be determined from
one of the following equations, depending on its material
of construction.

360.2
5-3 APPENDIX 5 — MANDATORY 5-5

Where Sn is expressed in psi, 5-3(f) Thinning of any flexible element as a result

of forming operations shall be considered in the design
and specifications of material thickness.

冧
2

冦
冤 冢 冣
28.3 ⴛ 106
ln Sn
Eb
− 14.12 冥 5-3(g) Extended straight flanges between the inner
N ≤ 47.11 exp and outer torus of flexible elements are permissible.
1.023
Extended straight flanges with lengths in excess of 0.5
冪Rt shall satisfy all the requirements of UG-27 where
tp uncorroded thickness of expansion joint straight
Where Sn is expressed in MPa, flange, in. (mm)
Rp inside radius of expansion joint straight flange

冧
2

冦
冤 冢 冣
19.5 ⴛ 104
ln Sn
Eb
− 9.143 冥 at the point of consideration, in. (mm)
p Ra or Rb
N ≤ 47.11 exp
1.023

for Series 3XX high alloy steels, nickel–chromium iron
alloy, nickel–iron chromium alloy, and nickel–copper
alloy for metal temperatures not exceeding 800°F
(427°C).1
Where Sn is expressed in psi,
5-4 FABRICATION
The following requirements shall be met in the
fabrication of expansion joint flexible elements.
5-4(a) All welded joints shall comply with require-
ments of UW-26 through UW-36.
5-4(b) All longitudinal and circumferential weld
seams shall be full penetration welds, Type (1) of

冧
2

冦
冤 冢 冣
30 ⴛ 106 Table UW-12.
ln Sn
Eb
− 15.18 冥 5-4(c) Longitudinal welds shall be ground flush and
N ≤ 12.26 exp smooth on both the inside and outside surfaces prior
2.317
to being formed into expansion elements.
5-4(d) Other than the shell attachment welds and
flange welds, no circumferential welds are permitted
Where Sn is expressed in MPa,
in the fabrication of the flexible elements, i.e., inner
torus, annular plate, and outer torus, unless the welds

冧
2

冦
冤 冢 冣
20.7 ⴛ 104
ln Sn
Eb
− 10.203
N ≤ 12.26 exp
2.317
for carbon, low alloy, Series 4XX, and high alloy steels
for metal temperatures not exceeding 700°F (371°C).
In the above formulas:
Np the required design life of the joint in cycles.
N shall not be less than 100 cycles.
Ebp modulus of elasticity used in the stress evalua-
tion of the expansion joint, psi (MPa)
5-3(d) The knuckle radius ra or rb of any formed
element shall not be less than three times the element
thickness t as shown in Fig. 5-1 unless the increased
bending stress due to curvature is accounted for by a
fatigue strength reduction factor.
5-3(e) The spring rate, lb /in. (N/mm), of the expan-
sion joint assembly may be determined either by calcula-
tion or by testing.
1
Temperatures may be exceeded if substantiated by elevated tempera-
ture fatigue test data or design curves using the U-2(g) approach.
冥 are ground flush and fully radiographed.
5-4(e) Flexible elements shall be attached by full
penetration circumferential welds.
5-4(f) Nozzles, backing strips, clips, or other attach-
ments shall not be located in highly stressed areas of
the expansion joint, i.e., inner torus, annular plate, and
outer torus. Nozzles or other attachments located in
the outer straight flange shall satisfy the axial spacing
requirements of Fig. 5-2.
5-4(g) Alignment tolerances of the completed expan-
sion joint attached to the shell shall meet the tolerances
specified by UW-33.
5-5 INSPECTION AND TESTS
5-5(a) All expansion joint flexible elements shall be
visually examined and found to be free of unacceptable
imperfections, such as notches, crevices, weld spatter,
etc., which may serve as points of local stress concentra-
tion. Suspect surface areas shall be further examined
by liquid penetrant or magnetic particle examination.
5-5(b) Longitudinal welds shall be fully radiographed
in accordance with UW-51. All full penetration butt

360.3
5-5 2001 SECTION VIII — DIVISION 1 5-6

1
/2
Min. ⫽ 0.2 (Rt )
1
/2
Min. ⫽ 0.2 (Rt )

t t

R R

(a) Nonreinforced Nozzle (b) Reinforced Nozzle

R ⫽ inside radius of expansion joint straight flange, in. (mm)

t ⫽ uncorroded thickness of expansion joint straight flange, in. (mm)

FIG. 5-2 TYPICAL NOZZLE ATTACHMENT DETAILS SHOWING MINIMUM LENGTH OF STRAIGHT FLANGE

type welds shall be examined 100% on both sides by
the liquid penetrant or magnetic particle methods after
forming.
5-5(c) The circumferential attachment welds between
the expansion joint and shell shall be examined 100%
on both sides by liquid penetrant or magnetic particle
examination.
5-5(d) The completed expansion joint shall be sub-
jected to a pressure test in accordance with UG-99.
The pressure testing of an expansion joint may be
performed as a part of the final vessel hydrostatic
pressure test provided the joint is accessible for inspec-
tion during pressure testing.
5-5(e) Expansion joint restraining elements [see Fig.
5-1 sketch (b)] shall also be pressure tested in accord-
ance with UG-99 as a part of the initial expansion
joint pressure test or as a part of the final vessel
hydrostatic pressure test after installation of the joint.
5-5(f) In addition to inspecting the expansion joint
for leaks during the pressure test, flanged and flued or
flanged only expansion joints shall be inspected before,
during, and after the pressure test for visible permanent
distortion.
5-6 STAMPING AND REPORTS
When the expansion joint is manufactured by other
than the vessel Manufacturer, the Manufacturer of the
expansion joint shall have a valid ASME Code U
Certification of Authorization and shall complete a Form
U-2 Manufacturer’s Partial Data Report, as required by
UG-120(c). A copy of this Partial Data Report shall
be attached to and become a part of the Form U-1 or
U-1A Manufacturer’s Data Report for the completed
vessel.
5-6(a) The Manufacturer’s Partial Data Report shall
include the following additional data and statements:
5-6(a)(1) maximum allowable working pressure,
psig, at °F;
5-6(a)(2) spring rate, axial movement (+ and −),
fit-up, and loading conditions for which the expansion
joint is designed;
5-6(a)(3) service conditions or restrictions;
5-6(a)(4) design life, cycles;
5-6(a)(5) the Partial Data Report, in addition to
recording the Manufacturer’s serial number, shall iden-
tify the vessel Manufacturer and specific vessel design
for which the expansion joint is intended;
5-6(a)(6) a certification that the expansion joint
has been constructed to the rules of this Appendix.
5-6(b) The parts Manufacturer shall identify the
expansion joint with the following:
5-6(b)(1) name of parts Manufacturer;
5-6(b)(2) serial number;
5-6(b)(3) maximum allowable working pressure,
psig, at °F;
5-6(b)(4) ASME U Symbol Stamp above the word
“Part,” as required by UG-116(i).
5-6(c) The identification stamping shall not be located
on the flexible elements of the expansion joint.

360.4