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UK branch:

High quality customized solutions...Belman and John Cardwell design and manufacture metallic expansion joints and bellows.

Expansion joints are an important component in various industries, and found extensively in power plants, nuclear power plants, exhaust- and engine systems, steel plants, district heating systems, chemical- and petrochemcal plants and steam distribution pipe work.

An expansion joint is a fl exible component which is used to prolong the plant life by reducing stress in pipe work as it expands and contracts. Compen-sators are also installed to protect sensitive equipment such as pumps and steam turbines.

We provide high quality compensators custom-made from DN 40 to DN 6000 operating at pressures from vacuum to 110 Bar. Many designs are avail-able: 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 manu-facture 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 identifi ca-tion (PMI).

From your detailed specifi cations or basic informa-tion 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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Alwaysa solution for you

Design and manufacture of metallic expansion joints is the core competence of our companies, as a total provider of fl exible solutions we also supply:

Fabric expansion joints Metallic hose assemblies Rubber expansion joints

Pipe work designFor our clients to be able to select the cost-effective 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 (FEA). This service is offered in association with a cooperative partner with great experience in this fi eld. Pipe design and stress analysis is carried out using among others Rohr2, Cesar and Ansys software.

On-site installation servicesInstallation of metallic expansion joints and in particular clamshell repair bellows requires skilled and experienced installation staff.Often clients prefer that the manufacturer car-ries out such installation work to avoid errors and focus responsibility on a single source.

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.

InspectionOur 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 replace-ment compensators.

Refurbish / repair existing compensatorsOur 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 restrain-ing 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 applicationsWe are always pleased to discuss the speci-fi cation, design, manufacture and use of our equipment to establish the optimum solutions to problems. Where this requires discussion at site or at our clients offi ces we are pleased to visit and make recommendations.

All in one

The combined experience of Belman and John Cardwell in the fi eld 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 satisfi ed with the products, services and technical support provided. Both compa-nies are strong and preferred brands globally. The combination of the resources of the two companies brings even greater strength to each companys 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 benefi t 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 ones 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 trans-port logistics limit the available size of fi nished

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 tech-niques.

Assured-quality expansion jointsBelman and Cardwell hold various certifi cates: 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 and is registred in Achilles JQS.

A strong connection

Nuclear power stationThese 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 150Built-in length: 300 mm.Medium: WaterDesign temperature: 100C.Design pressure: 6 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 move-ments 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 Tefl on sliding blocks between the two pipes, which add stability to the expansion joints.

Dimension: NB 900 and NB 1000Built-in length: 1370 to 1670 mm.Medium: Air.Design temperature: 120C.Design pressure: -1/1 bar.

Coal fi red power station

High Pressure Heater Bled Steam Bellows are installed in a coal fi red power station. The com-pensators 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 225Built-in length: 340 mm.Medium: Steam.Design temperature: 377C.Design pressure: 5 bar.

Exhaust systemThis expansion joint is installed near the engine in an exhaust system on a ship. The expansion joint is supplied as an OEM part, which explains the special fl anges. These fl anges are special as they must fi t the counter fl anges of the engine.

Dimension: NB 150Built-in length: 66 mmMedium: -Design temperature: 700CDesign pressure: 1 bar

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 di-rection 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 bel-lows, lateral movement is absorbed by equal and opposite angular rotation of the line bellows.

Dimension: NB 1400Built-in length: 7574 mm.Medium: Steam.Design temperature: 200C.Design pressure: Full vacuum/2,0 bar.

Exhaust systemThese expansion joints are installed near the engine in the exhaust system on a FREMM Fregat ship. The expansion joint will absorb axial and lateral movement.

Dimension: NB 500Built-in length: 600 mmMedium: -Design temperature: 550CDesign pressure: 1 bar

Chemical industryThis Gimbal expansion joint is installed at a chemi-cal plant in South Africa. During shutdown the plant was in urgent need of new expansion joints. Belmans fast tracks service resulted short time of delivery. Before dispatch the expansion joints was among others pressure tested for 150 bar.

Dimension: NB 300Built-in length: 800 mmMedium: -Design temperature: 120CDesign pressure: 100 bar

Customized solutions

References

Chemical industryThese chamber compensators are installed at an asphalt manufacturer in France. Asphalt is diffi cult to keep fl owing; therefore the temperature has to be very high. The compensator is a double com-pensator 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 fl owing through the compensator.

Dimension: NB 125 and NB 175 Built-in length: 365 mm and 232 mm.Medium: Asphalt (Bitumen).Design temperature: 200C.Design pressure: 6 bar.

Steel plantThis 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 move-ments 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.

Dimension: NB 2200 Built-in length: 6930 mm.Medium: Blast furnace gas.Design temperature: 300C.Design pressure: 2,2 bar.

Steam turbineTwo 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 2000 Built-in length: 5500 mm.Medium: Steam.Design temperature: 250C.Design pressure: Full vacuum/1 bar.

Oil refi nery These refractory lined expansion joints are installed at an oil refi nery. The need for these compensators has occurred in connection with modernization of a FCC unit. Compensators are installed at one of the fl ue gas channels going from the FCC reactor and have similar technical characteristics apart from the length. All compensators were pre-stressed.

Dimension: NB 1900 Built-in length: From 450 to 500 mm. Medium: Flue gas.Design temperature: 650 to 1000C.Design pressure: 0,01 bar.Lining: Golit 135R light weightInsulation: Super wool n607 HT

Customized solutions

These project highlights and their satisfi ed customers might explain why you should also chose us:

Fast track serviceAn oil refi nery had a leaking expansion joint. Within 24 hours we had designed, manufactured and dis-patched a new expansion joint. The system was re-stored to its full operating capacity shortly afterwards.

AdviceWe worked with a steel plant to advice on a com-pensators design and positioning, as a result of our discussions with the client a costly unscheduled shut down of the plant was avoided.

Full scale documentationNational regulations resulted that full scale documen-tation was required for a nuclear power station in Sweden. Belman collected comprehensive andneeded documentation, test reports etc for the satis-faction of the customer.

Solving unacceptable maintenance and down timeA train manufacturer had problems with exhaust gas expansion compensators that kept breaking and constantly required replacement.

This proved to be time consuming and expensive, but also posed a health risk to people near the mov-ing trains. After design, prototyping, on-vehicle test-ing then fi nally approval for full scale manufacture, we have solved our clients problem. The units are now in service and are proving to be living up to the clients expectations.

Help on installationA steel plant needed a repair unit for a leaking bel-low. Our installation team fi tted an oversize clamshell bellows around the leaking bellow, the problem was solved and without any cost full down-time at all.

Project highlights

Belman Production A/SOddesundvej 186715 Esbjerg N DenmarkT: +45 7515 5999 F: +45 7515 5959

www.belman.dk

John Cardwell Limited Buildbase WayBird Hall Lane, Cheadle HealthStockport, CheshireSK3 0SBUnited KingdomT: +44 (0) 161 491 5515F: +44 (0) 161 491 2354

www.john-cardwell.co.uk

Compensator technology worldwideBelman 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 offi ces around the globe. For information on Belman and John Cardwell partners worldwide,

please contact us at belman@belman.dk or +45 7515 5999

ISO 9001 REGISTERED

DNV Certification BV 013