Expansion joints for tthe power sector
High quality customized solutions ... Belman and John Cardwell design and manufacture metallic expansion joints and bellows. Expansion joints are an important component in the energy sector and are found extensively in coal-fired and nuclear power plants as well as CHP installations. They are also used widely in steel plants, district heating systems, chemical and petrochemical plants, steam distribution pipe work and building services. An expansion joint is a flexible component which is used to prolong the plant life by reducing stress in pipe work as it expands and contracts. Compensators are also installed to protect sensitive equipment such as pumps and steam turbines. We provide high quality compensators custommade from DN 40 to DN 6000 operating at pressures from vacuum to 110 Bar. Many designs are available: ● Round and rectangular bellows. ● From simple axial units to complex in-line and corner-relief pressure-balanced compensators. ● Externally pressurised compensators. ● Bellows protected by Tantal- and PTFE where corrosion considerations dictate. A wide range of material is used for bellows manufacture including 300 stainless steels, titanium, high-nickel alloys such as Inconel, Incoloy, Hastelloy, Monel etc. All compensators covered by the requirements of the Pressure Equipment Directive (97/23/EC) are CE-marked and our design process includes: ● Calculation according to EJMA, EN 13445, ASME, AD 2000 or EN 14917. ● CAD drawings. ● 3D illustrations. ● Finite Element Analysis. ● Discussion with clients to advise on all aspects of compensator design and application. Non-destructive testing is carried out according to project requirements, this includes: Radiographic examination of welds, hydrostatic pressure testing, air leak and air jet testing, helium leak testing, dye penetrant examination, ultrasonic testing, magnetic particle examination and positive material identification (PMI). From your detailed specifications or basic information about your requirement we will work with you to design the optimum compensator solution. We will give advice on compensator type, its location in the pipe work and all installation requirements.
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Always a solution for you All in one Design and manufacture of metallic expansion joints is the core competence of our companies, as a total provider of flexible solutions we also supply: ● ● ●
Fabric expansion joints Metallic hose assemblies Rubber expansion joints
Pipe work design For our clients to be able to select the costeffective and operationally sound solutions to expansion compensation we can, in addition to providing advice on compensator selection and application, assist with pipe work design and stress analysis. This service is offered in association with a cooperative partner with great experience in this field. Pipe design and stress analysis is carried out using among others Rohr2, Cesar and Ansys software.
We have a site team of skilled welders to carry out such work, the team is experienced, familiar with site working and complying with site safety procedures.
On-site installation services
Installation of metallic expansion joints and in particular “clamshell” repair bellows requires skilled and experienced installation staff. Often clients prefer that the manufacturer carries out such installation work to avoid errors and focus responsibility on a single source.
Our site people undertake inspection of existing compensators. Inspection reports are provided with comments on the condition of the units together with any recommendations for improvements, repairs or remedial action including planning for replacement compensators.
Refurbish / repair existing compensators Our clients often ask us to bring existing compensators back to an “as-new” condition by removing the existing bellows elements and replacing with new. This practice allows the cost of manufacturing new pipe work components and any restraining structure to be avoided. It is often used as a fast solution to get the plant back on line quickly when a bellows element in a compensator has reached the end of its life.
Assistance with compensator applications We are always pleased to discuss the specification, design, manufacture and use of our equipment to establish the optimum solutions to problems. Where this requires discussion at site or at our clients’ offices we are pleased to visit and make recommendations.
A strong connection The combined experience of Belman and John Cardwell in the field of expansion joint design and manufacture is over 42 years. During this period many compensator projects have been successfully completed and many customers have been satisfied with the products, services and technical support provided. Both companies are strong and preferred brands globally. The combination of the resources of the two companies brings even greater strength to each company’s ability to provide the best solutions to customer requirements. Belman acquired John Cardwell in 2008, since then the companies have joined forces but each still operates as and individual entity for the benefit of its customers. Before the acquisition Belman and John Cardwell were cooperative partners, the synergy between the companies was recognised through this cooperation and when Belman had the opportunity to buy John Cardwell they did so. The combination of the companies strengthens each one’s ability to bring the most appropriate and cost-effective solutions to its customers. Belman has a production area of 5 300m2 with a lifting capacity of 30 tonnes and only transport logistics limit the available size of finished
compensators. John Cardwell has a facility of 2200 m2 and together the companies employ a highly-skilled workforce of around 125 people. Together we manufacture metallic bellows using rolling, punching and hydraulic forming techniques.
Assured-quality expansion joints Belman and Cardwell hold various certificates: ● DS/EN ISO 9001:2000 ● BS / EN / ISO 2001:2000 ● UKAS ● PED 97/23/EC Module H ● EN 3834 ● AD2000 HP0 ● GOSR-R ● Russian “Permission for application within hazard industries” ● Mark transfer approval within EN 10204 3.1.B PED/AD-M W ● Standard type approvals from Germanischer Lloyd ● Standard type approvals from Bureau Veritas. Belman is a member of EURO-QUALIFLEX
Customized solutions for the power sector Power plant These red corner relief expansion joints are installed in a power plant in Sweden, this type of compensator is installed at a suitable change of direction in the pipe work. The unit shown is suitable for combined axial and lateral movements, if axial movement only is required then the two bellows at the line side can be replaced by a single bellows. As the pipe expands the axial movement is taken up by equal compression of the two bellows and a corresponding total extension of the balance bellows, lateral movement is absorbed by equal and opposite angular rotation of the line bellows. Dimension: NB 1400 mm. Built-in length: 7574 mm. Medium: Steam. Design temperature: 200ºC. Design pressure: Full vacuum/2,0 bar.
▲ Pantographic gimbal for district heating 35 expansion joints, like the picture shows, were supplied with up to four bellows and pantographic gimbal for a district heating pipeline in France. More bellows allow the absorption of very large movements but in order to ensure uniform running of the bellows and thus equal absorption of movements pantographic gimbal have been mounted. In this way it can be avoided that some bellows absorb larger movements than others and wear out prematurely. The large number of bellows leads to instability, which the pantographic gimbal cannot compensate for, but the construction of the pipeline brings about a stabilisation of the expansion joint. This is due to the fact that it has been possible to place Teflon sliding blocks between the two pipes, which add stability to the expansion joints. Dimension: NB 900 and NB 1000 mm. Built-in length: 1370 to 1670 mm. Medium: Air. Design temperature: 120ºC. Design pressure: -1/1 bar.
Nuclear power station These gimbal expansion joints are installed in the secondary system in a nuclear power station in Switzerland. The expansion joints are designed and manufactured according to Swiss national standards. Dimension: NB 150 mm. Built-in length: 300 mm. Medium: Water Design temperature: 100ºC. Design pressure: 6 bar. ▲ Coal fired power station ”High Pressure Heater Bled Steam Bellows” are installed in a coal fired power station. The compensators are installed between heater and boiler. The bellow is made of Incoloy 825 to avoid stress corrosion and the compensator has a customized thermal shield inside in stainless steel. The bellows are internally and externally pressurized. Dimension: NB 225 mm. Built-in length: 340 mm. Medium: Steam. Design temperature: 377ºC. Design pressure: 5 bar.
Electric power plant This specially designed compensator is installed at an electric power plant in Germany; it is installed near to the steam turbines. The customized design is an axial compensator with the pressure applied of the external surface of the bellows instead of the conventional internally pressurised arrangement. Fluid can be completely drained from the bellows with this arrangement. Dimension: NB 500 mm. Built-in length: 730 mm. Medium: Steam. Design temperature: 250°C. Design pressure: 12 bar.
Nuclear power station These universal compensators are installed at the steam turbines in a nuclear plant in Sweden. The compensators are not directly in contact with the radioactive media, as they are installed in the secondary system of the plant. Dimension: NB 800 mm. Built-in length: 2195 mm. Medium: Steam. Design temperature: 110ºC. Design pressure: -1/2,5 bar.
District heating pipeline Lateral expansion joints installed in a district heating pipeline in Germany. Dimension: NB 800 mm. Built-in length: 2200 mm. Medium: District heating water. Design temperature: 136ºC. Design pressure: 25 bar.
Customized solutions for other industries Steel plant
This 12,5 tonnes heavy customized solution is installed near the blast furnace at a steel plant in Germany. The pipes for the blast furnace is placed in the height of 30 meters and the compensator is installed ahead of the pipe bend in the horizontal pipe. Here it absorbs lateral and angular movements together with a smaller expansion joint. On top of the pipeline a footbridge is placed. The manhole on top of the large compensator is an inspection hole. Through that the inspection people can get access to the internal part of the pipeline during inspections.
These refractory lined expansion joints are installed at an oil refinery. The need for these compensators has occurred in connection with modernization of a FCC unit. Compensators are installed at one of the flue gas channels going from the FCC reactor and have similar technical characteristics apart from the length. All compensators were pre-stressed. Dimension: NB 1900 mm. Built-in length: From 450 to 500 mm. Medium: Flue gas. Design temperature: 650 to 1000°C. Design pressure: 0,01 bar. Lining: Golit 135R light weight Insulation: Super wool n607 HT
Dimension: NB 2200 mm. Built-in length: 6930 mm. Medium: Blast furnace gas. Design temperature: 300ºC. Design pressure: 2,2 bar.
Chemical industry These chamber compensators are installed at an asphalt manufacturer in France. Asphalt is difficult to keep flowing; therefore the temperature has to be very high. The compensator is a double compensator where the asphalt is running in the inner chamber, while hot oil runs in the outer chamber. In that way the asphalt is kept hot and flowing through the compensator.
Steam turbine Two 6,3 tonnes heavy corner relief expansion joints like this one are installed in a steam turbine in Singapore. The compensators is installed between the turbine and the condenser.
Dimension: NB 125 mm and NB 175 mm. Built-in length: 365 mm and 232 mm. Medium: Asphalt (Bitumen). Design temperature: 200ºC. Design pressure: 6 bar.
Dimension: NB 2000 mm. Built-in length: 5500 mm. Medium: Steam. Design temperature: 250ºC. Design pressure: Full vacuum/1 bar.
Project highlights These project highlights and their satisfied customers might explain why you should also chose us:
Solving unacceptable maintenance and down time
Fast track service
A train manufacturer had problems with exhaust gas expansion compensators that kept breaking and constantly required replacement.
An oil refinery had a leaking expansion joint. Within 24 hours we had designed, manufactured and dispatched a new expansion joint. The system was restored to its full operating capacity shortly afterwards.
Advice We worked with a steel plant to advice on a compensator’s design and positioning, as a result of our discussions with the client a costly unscheduled shut down of the plant was avoided.
Full scale documentation National regulations resulted that full scale documentation was required for a nuclear power station in Sweden. Belman collected comprehensive and needed documentation, test reports etc for the satisfaction of the customer.
This proved to be time consuming and expensive, but also posed a health risk to people near the moving trains. After design, prototyping, on-vehicle testing then finally approval for full scale manufacture, we have solved our client’s problem. The units are now in service and are proving to be living up to the client’s expectations.
Help on installation A steel plant needed a repair unit for a leaking bellow. Our installation team fitted an oversize clamshell bellows around the leaking bellow, the problem was solved and without any cost full down-time at all.
Compensator technology worldwide Belman and John Cardwell are bringing solutions to customers within all kinds of industries throughout the world. These customers are serviced via our network of partners, own sales people and offices around the globe. For information on Belman and John Cardwell partners worldwide, please contact us at firstname.lastname@example.org or +45 7515 5999
ISO 9001 REGISTERED
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Belman Production A/S Oddesundvej 18 6715 Esbjerg N Denmark T: +45 7515 5999 F: +45 7515 5959 www.belman.dk
John Cardwell Limited Buildbase Way Bird Hall Lane, Cheadle Health Stockport, Cheshire SK3 0SB United Kingdom T: +44 (0) 161 491 5515 F: +44 (0) 161 491 2354 www.john-cardwell.co.uk