FATIGUE LIFE EXPECTANCY

The fatigue lite expectancy of an Expansion Joint is affected by various

factors such as: operating pressure, operating temperature, the material from
which the bellows is made. the movement per convolution, the thickness of
the bellows, the convolution pitch, and the depth and shape of the
convolution. Any change in these factors will result in a change in the life of
the Expansion Joint.
The fatigue life expectancy can be defined as the total number of complete
cycles which can be expected from the Expansion Joint based on data
tabulated from tests performed at room temperature under simulated
operating conditions. A cycle is defined as one complete movement from the
initial position in the piping system to the operating position and back to the
initial position. Fatigue life is dependent upon the maximum stress range to
which the bellows is subjected, the maximum stress amplitude being a far
less sianificant factor.
Expansion Joints can be specially designed for very high cyclic life. When
this is required, the Expansion Joint manufacturer must be advised of the
estimated
number of cycles required.
The equations given for fatigue life should only be used when the actual
bellows metal temperature under operating conditions is below the creep
range. Fatigue life calculations for actual bellows metal temperatures in the
creep range must be substantiated by high temperature test data or history of
successful operation of a similar bellows size and configuration for identical
or more severe service.
a.

FATIGUE LIFE
The fatigue life of a bellows is a function of the sum of the meridional
pressure stress range and the total meridional deflection stress range.
The deflection stress range must be based on the total equivalent axial
movement range as discussed in Section 4.3.

b.

The number of cycles to failure may be evaluated by equations (4-34),

(448) and (4-59). The constants are derived from graphs of the total
stress range versus number of cycles to failure from actual fatigue
tests of a series of bellows of similar materials at room temperature
evaluated by a best fit continuous curve. These equations are meant to
predict the
average fatigue life for the bellows design. Certain codes and
standards
incorporate design fatigue curves which include factors that account
for
the normal effects of size, surface finish and scatter of the data.
Therefore,
the design cycle life should realistically represent the estimated number
of
operating cycles. An overly conservative estimate of cycles can result in
an increased number of convolutions and an Expansion Joint more prone
to instability.

CUMULATIVE FATIGUE
An Expansion Joint may
be required to withstand a
number of stress cycles
such as those produced by
the start up and shut down

of the system. While these cycles usually control the fatigue life of the
bellows, there may be instances where other conditions assume
importance in

determining the overall or cumulative fatigue life of

the bellows. As an
example. one condition may generate 1,000 cycles of
stress variation from zero to 160.000 psi and another
condition 10,000 cycles of stress variation from zero to
50,000 psi. The procedure described in the following
paragraphs illustrates the method used in evaluating the
fatigue damage in a bellows when it is subjected to a
variety of conditions during its lifetime. This method is
based on Minor's HypothesisT which is generally
accepted as sufficiently accurate for predicting the
effect of cumulative fatigue.
The method assumes that a stress versus fatigue life
curve has been
established for the type of bellows under consideration.
c.

CONCURRENT CONDITIONS
Concurrent conditions are those that occur at exactly
the same time and frequency producing a combined
stress range. The stress ranges for each condition are
superimposed to give cases of combined stress range
for the applicable number of cycles. Truly concurrent
conditions are rare in
practice. If the conditions described in the above
example are concurrent. the cumulative effect can be
evaluated using the following steps:
Step I: Superimpose the stress range of each
condition for the applicable number of cycles to find
each case as follows:
Case 1:

r1, =1000 cycles

=1160. 0001+150, 0001
= 210,000 psi stress range

Case 2:
cycles

n, =10.000-1000 = 9000

S ,.

=101+150,0001
= 50,000 psi stress range

Step 2: For each stress range Si/. Sp,......... , use the

applicable fatigue curve to find the number of cycles
to failure NI, N2, ... for each case.
Step 3: For each case, calculate the usage factor U1,
U,, ... where U1=
n,/NI, U2 =
etc.
Step 4: Calculate the cumulative usage factor where U =
U1 + U, +

Step 5: The cumulative usage factor U shall not exceed

1.0.
d.

INDEPENDENT CONDITIONS
Independent conditions are those that do not occur at
exactly the same time or frequency. Independent
conditions are not superimposed. Most conditions in
practice are independent. if the conditions described
in the above example are independent, the cumulative
effect can be evaluated using the following steps: