belman@belman.com
CEMENT INDUSTRY
EXPANSION JOINTS
Expansion Joints for the cement industry are used in a wide variety of applications. Through numerous projects for cement plants, Belman has gained extensive experience with a wide range of installation purposes.
Applications:
- Kiln inlet and outlet ducts
- Preheater and calciner systems
- Raw mill and cement mill ducting
- Tertiary air ducts (TA ducts)
- ID, FD, and process fans
- Dust collection and baghouse connections
- Bypass ducts and gas conditioning towers
Design expertise:
- High pressure
- High temperatures
- Special media compositions
- Special material requirements
- Custom Metallic Expansion Joints and Fabric Expansion Joints
Design range and scope of supply within cement industry Expansion Joints
The capability design range for Belman and cement industry Expansion Joints are:
DIMENSIONS:
DN 25 – DN 6000
(Belman range:
DN 25 – 12.000)
PRESSURE:
From full vaccum up to 50 barG
(Belman range:
From full vaccum up to
250 barG or more if required)
TEMPERATURE:
From -25°C to +500°C
(Belman range:
from -269°C to +1000°C)
MATERIALS:
All austenitic stainless steels including 1.4571 (AISI 316Ti), 1.4541 (AISI 321), 253 MA (1.4835) and Hastelloy C-4
DESIGN CODES:
EN 13445, EN 13480, EN 14917
ASME VIII, div.I, ASME B31.3
ASME B31.1, EJMA, AD 2000
and others on request
TESTS:
Radiographic examination (X-ray), Helium leak testing, Pressure test, Air test, Dye penetrant test, Magnetic particle examination and many more
CEMENT INDUSTRY EXPANSION JOINTS
CASE STORY
These high-pressure Hastelloy Expansion Joints were the perfect solution for a cement plant in Germany. These large-sized DN 600 and DN 550 Expansion Joints are 2.5 meters long. High requirements were placed on the Expansion Joint design as well as on the testing due to extremely high-pressure operating conditions together with the requirement that they absorb large axial movements. As per the client’s specifications, the Bellows and the inner sleeves are made from Hastelloy C-4 – a material with outstanding high temperature stability as well as high ductility and corrosion resistance.
REFERENCES
Cementa • JK Lakshmi Cement • KJS Cement • JSW Group • Nuveco • ACC • Dalmia Cement • Dangote Cement • Sidhee Cement
Uhde High Pressure Technologies • Ambuja Cement • Goldstone Cement • Amrit Cement • Sagar Cement • Chettinad Cement • Toshali Cement • Norcem • Fuller (FLSmidth)
TECHNICAL DESCRIPTION
TYPES & DESIGN
The Expansion Joint types and designs used in cement plant applications include both standard catalogue Expansion Joints as well as fully customised Expansion Joints tailored to specific application requirements. However, the main types of Expansion Joints which, in Belman’s experience, are used in these industries are:
- Untied Expansion Joints
- Lens Expansion Joints
- Ring Reinforced Expansion Joints
- Fabric Expansion Joints
- Rectangular Expansion Joints
Customised cement plant Expansion Joint solutions
In most projects, Belman is brought in to assist with identifying the optimal solution for the application. This often requires custom-designed Expansion Joints, engineered specifically to address the challenges of complex and critical piping systems. Due to varying media compositions and diverse operating conditions, the design and features of the Expansion Joints can differ significantly from one project to another. Belman specialises in developing tailored solutions that meet the exact needs of both the client and the application.
MATERIALS
Expansion Joints for cement plants are primarily manufactured from austenitic stainless steels or heat resistant steels. The choice of material depends on the specific design and the application requirements in regard to all components, including the Bellows, inner sleeves, flanges, middle pipes and welding ends. Belman can design and manufacture Expansion Joints for cement plants from the following materials:
- All austenitic stainless steels including 1.4571 (AISI 316Ti), 1.4541 (AISI 321) etc.
- 253 MA (1.4835)
- Hastelloy C-4
ADVANTAGES
- The correct Expansion Joint solution for the application
- Customised in all kinds of materials, even special alloys
- Cost-efficient solution for the applications
PRODUCT
BROCHURE
GET THE
CATALOGUE
QUALITY & TESTS
Belman is known for high quality products and therefore our quality control is a fundamental part of our business. All processes during production designed by the Belman quality engineers, is strictly follow and implement according our procedures and instructions and carefully inspected by Belman quality inspectors. All checks and inspections are done according to the strict prevailing Belman quality control procedures which is part of the Belman ISO 9001 quality management system approved by DNV.
ITP & Test
Inspection test Plan generated by the quality management system makes sure that each step of manufacturing has the appropriate inspection points such as Hold and Witness points.
Based on manufacturing code, project specification, application, media, and eventual ship classification rules Belman performs a large variety of quality tests including destructive, non-destructive testing and proof testing. All tests can be witnessed by the 3rd part based on the customer and classification requirements.
- Destructive test: such as life cycle test and burst test to validate the design, i.e., vessels and offshore platforms
- Non-destructive test such as Visual testing, dye penetrant test, Radiography examination, Magnetic testing, ultrasonic testing, hardness testing and PMI for all applications
- Proof tests: leak test with air, leak test with helium and formier gas, hydrostatic pressure test for all application
FABRIC EXPANSION JOINTS
In cement plants, Fabric Expansion Joints are widely used alongside Metallic Expansion Joints. So as to offer a complete product range to cement plants, Belman also designs, produces and supplies a wide range of Fabric Expansion Joints. Fabric Expansion Joints offer superior flexing capabilities compared to other solutions and can be made from a variety of special woven fabrics, which are coated or laminated with selected elastomers or fluoropolymers. Fabric Expansion Joints are used to insulate, to avoid mechanical loads and to protect against abrasion. They offer advantages for the pipework designer as they can absorb movements simultaneously in several directions. In addition, they have almost no reactive forces and require little space. Fabric Expansion Joints are easy to customise to suit existing operating conditions and are easy to transport and install in piping and ducting systems. In comparison to Metallic Expansion Joints, Fabric Expansion Joints offer almost unlimited flexibility, giving the pipework designer more options. Fabric Expansion Joints can be installed in systems that operate with low pressure and dry media.
WE HAVE ENGINEERED
EXPANSION JOINTS SINCE 1994
This enables us to find you the optimum solution to your piping system.