RENOVATION OF A SPECIALLY DESIGNED EXPANSION JOINT
Steel plant
Germany
EJMA
For a long-standing client, a steel plant in Germany with multiple Belman Expansion Joints installed, Belman assisted in renovating one of its DN 2600 Expansion Joints (which was actually not an Expansion Joint originally produced by Belman). This renovation provided the client with significant cost savings and a positive environmental impact, due to less scrap.
CLIENT ISSUE
The client contacted Belman with a request to renovate a large DN 2600 Expansion Joint featuring a complex cooling piping system. The Bellows were leaking, necessitating their replacement, while the rest of the Expansion Joint was in good condition. Therefore, the client opted for a renovation as a smart solution and was looking for a capable and experienced supplier for the task. As the client already knew Belman for its capability and expertise in handling complex and large Expansion Joint designs along with its reputation for high quality, craftmanship and on-time delivery, Belman was selected by the client as the preferred supplier for this job.
BELMAN SOLUTION – Renovating the Expansion Joint
New Bellows made from 253 MA
As the Expansion Joint absorbs multiplane movement, the new Bellows are designed for axial and angular movement in combination. As per client request, the bellows are made from the material 253 MA, which is a lean austenitic heat resistant alloy with high strength and outstanding oxidation resistance. It combines excellent service properties at high temperatures with ease of fabrication and resists oxidation at temperatures up to 1150°C.
The Expansion Bellow renovation process
The client dismounted the Expansion Joint from its location in the hot blast pipeline and removed the refractory lining from the inside of the Expansion Joint. After attaching transport bars, it was shipped to Belman. Upon arrival of the Expansion Joint Belman conducted a visual inspection, took measurements and photo documentation to ensure accurate reassembly. This confirmed that only the Bellows and inner sleeves needed replacing. The hardware was in good condition and needed only sandblasting and coating. After agreeing on the scope of the work and timeline, Belman began dismantling the Expansion Joint as well as producing and testing the new Bellows.
During the dismantling process, the piping system around the Expansion Joint used for blowing cold air into the system was removed, flanges were covered, and the existing Bellows were cut out as well as the welds cut off. A PMI test was conducted at the weld cut-off points, and to accommodate the larger gap, the new bellows were made with a longer tangent. Inner sleeves were removed and the hardware was dismounted. The hardware parts were sandblasted and, upon their return to Belman, reassembled along with the new Bellows and inner sleeves. Since the hardware parts were reused, the refractory anchors for the refractory lining remained intact. This helped to simplify and speed up the renovation process.
The client requested the Expansion Joint be coated with GALVOSIL 15700, which is a two-component, solvent-borne, self-curing, inorganic zinc silicate with outstanding resistance against weathering and abrasion. After assembly, a coating was applied and the piping cooling system was remounted. Finally, the Expansion Joints were dispatched to the client for re-refractory lining and reinstallation in the hot wind pipeline of the steel plant.
Reuse as many parts of the Expansion Joint as possible
From both a financial viewpoint and an environmental perspective, it makes sense to reuse as much hardware as possible on the Expansion Joint. In this way all hardware was evaluated as applicable for reuse. This meant that only the bellows and the inner sleeves needed to be replaced, while the carbon steel parts were sandblasted and repainted. In this way the Expansion Joint handed back to the client was as good as new.
Why renovation is a smart solution for Expansion Joints with heavy and thick-walled hardware?
Refurbishment offers numerous advantages for Expansion Joints with heavy and thick-walled hardware. Some of the key reasons why renovation is often a smart choice are:
- Refurbishing existing components is significantly less expensive than manufacturing new ones. This approach helps to stretch budgets without compromising on quality
- Manufacturing new heavy and thick-walled hardware can be time-consuming. Refurbishment is typically faster, ensuring minimal downtime for critical operations and better time efficiency
- Extended lifespan, as the heavy and thick-walled hardware are designed for longevity, whereas with the bellows replaced, the service life of the Expansion Joint is extended, ensuring continued performance and reliability
- Choosing refurbishment over replacement reduces waste and minimises the environmental impact associated with manufacturing new parts, as the client avoids having to scrap fully functioning steel parts.
Belman – highly experienced in Expansion Joint refurbishments
With extensive experience in refurbishment projects since 1994, Belman stands as the premier choice for Expansion Joint renovations. An impressive track record assures clients the right solutions at the right cost, within the requested (or agreed) timeline. Leveraging extensive expertise, Belman accurately assesses which parts need replacement and which can be renovated and reused. Tailored advice is provided to clients, always considering both the project timeline and financial factors to ensure the best possible solution for the client. Belman carries out renovations of both Expansion Joints originally produced by Belman as well as Expansion Joints manufactured by other brands.
