BEST-IN-CLASS

EXPANSION JOINTS FOR EXHAUST GAS CLEANING (SCRUBBER)

Belman has vast experience in the design and manufacturing of Expansion Joints for exhaust gas cleaning (scrubbers). Exhaust gas cleaning systems are also known as scrubbers, scrubber systems, wet gas scrubbers, exhaust gas scrubbers among many other designations. No matter the designation, ithey have the same purpose: to control air pollution by cleaning the exhaust gas. Belman delivers Expansion Joints that ensure ship owners, shipyards and maintenance crews smooth, optimum and reliable operation of their cleaning systems in order to meet the emission limits of allowable emission in low-emission zones.

In scrubber systems, Expansion Joints are essential components. They accommodate movements and thereby protect the structural integrity of the scrubber, the connected pipelines and the connected equipment. At the same time, they must withstand high temperatures, aggressive chemicals and wet, acidic environments. This combination places strict demands on both the compensator design and material selection.

Belman has extensive experience in the design and manufacturing of Expansion Joints for exhaust gas cleaning systems onboard:

Container ships
Cargo vessels
Bulk carriers
Tankers
Cruise ships
Passenger ships

No matter the application, Belman – based on our extensive experience – can expertly design, manufacture and test Expansion Joints for you.

Design range and scope of supply within Expansion Joints for exhaust gas cleaning (scrubber)

Diameter, installation length and design criteria of Expansion Joints for exhaust gas cleaning (scrubber) can be changed upon the customer’s request and are available in:

DIMENSIONS:
For this application:
Typically DN 80 – 2.000

Belman general design size range:
DN 25 – 12.000

PRESSURE:
For this application:
Up to 0,5 barG

Belman general design pressure range:
full vacuum up to 150 barG

TEMPERATURE:
For this application:
+550°C / +300°C

Belman general design temperature range:
-256°C to +1000°C

MATERIALS:

For this application:
1.4571, 1.4539, 1.4404, 1. 4410,
254 SMO, Alloy 59, Duplex, Superduplex

General Belman material range:
All austenitic stainless steels and high alloyed steels

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.

Inspected by: DNV, BV, RINA, NK, KRS, Lloyd’s Register and many more.

ENGINEERED

EXPANSION JOINTS FOR
EXHAUST GAS CLEANING SYSTEMS (SCRUBBER)

Bellows for scrubber inlet and scrubber outlet

254 SMO expansion joints for scrubber systems

EXPANSION JOINTS FOR EXHAUST GAS CLEANING SYSTEMS (SCRUBBER) PROJECTS

CASE STORIES

SCRUBBER EXPANSION JOINTS

Expansion Joints for exhaust gas cleaning (scrubbers) for a passenger ship. Expansion Joints for scrubbers are often made from 254 SMO.

URGENT DELiVERY

A bulk carrier was in urgent need of a replacement Expansion Joint for its scrubber system. Belman helped out by offering an extremely short delivery time.

ALLOY 59 WAS THE SOLUTION

In some situations, austenitic steels and 254 SMO are not resistant to the media in the scrubber system. In those cases, Alloy 59 is the solution.

EXPERIENCED & APPROVED SUPPLIER

REFERENCES

Exhaust GAS CLEANING SYSTEMS (SCRUBBERS)

MAN Diesel & Turbo • MSC • Dresser-Rand • Kawasaki • Wärtsilä Gas Solutions • Samsung Heavy Industries • Peter Brotherhood • DFDS • Drydocks World • Maersk • Royal Caribbean Cruise Lines • Hyundai Heavy Industries • IHI Europe • Langh Tech • TORM • Baltec Marine • Fayard • AS LTH Baas • U.N. Ro-Ro İşletmeleri • ASTANDER • John T. Essberger • Jifmar Group •

YARA • PureteQ A/S • ME Production • CMA CGM • Dream Cruises • Stena • Southern Route Marine • SPX • Sembcorp Marine • Matson • Navios • Jubilant • Breeze Marine Group • Finnlines • P&O • Eastern Mediterranean Maritime • Chantiers Naval de Marseille • Grandi Navi Veloci • Grimaldi Lines • EMDEN DOCKYARD • Everly Holdings Venture Inc. •

See more references

EXPANSION JOINTS FOR SCRUBBERS

TECHNICAL DESCRIPTION

APPLICATIONS

Belman Expansion Joints for exhaust gas cleaning (scrubber) are typically installed in various exhaust cleaning system types on board marine vessels, such as:

Cruise liners
Container ships
Ferries
Cargo ships
Freighters
Passenger ships
Oil tankers, etc.

The installation of a scrubber can generate different movements and requirements for low nozzle loads on the scrubber. Therefore, the use of Expansion Joints plays an important role in protecting the scrubber and connected equipment against these movements and loads. The Expansion Joints for exhaust gas cleaning (scrubber) are therefore placed at different locations around the scrubber. No two scrubbers look exactly the same, and they are designed and manufactured in many different ways. The Expansion Joints are often installed before and after the scrubber. In most cases, they are positioned at the exhaust inlet and outlet as well as the process water inlet and outlet.

Both new and retrofit

Belman designs and manufactures Expansion Joints for both new build and retrofit projects. Our competence and expertise lie in the design and manufacture of customised Expansion Joint solutions with short lead times. As scrubber technology is now widely installed on both new and existing vessels, retrofit projects often require Expansion Joints that fit into limited space and existing pipelines.

TYPES & DESIGN

Belman designs and manufactures a wide range of Expansion Joints for scrubber applications. The type and size of Belman Expansion Joints for exhaust gas cleaning (scrubber) are determined by the dimension of the scrubber and its piping/duct work. Furthermore, the shape of the piping on the scrubber inlet and scrubber outlet and the design and type of the scrubber determines the type of Expansion Joints for exhaust gas cleaning (scrubber) needed. The design of the Expansion Joint is specified by the amount of movement, the media and the operating parameters in the system.

Design

For most applications, the Expansion Joints used are single Bellows or double Bellows Expansion Joints with loose flanges. They are mainly suitable for absorbing axial movements. The designs mainly used are:

SINGLE BELLOWS WITH LOOSE FLANGES

This type absorbs axial movements in the scrubber system. Other connection ends are available on request.

DOUBLE BELLOWS WITH LOOSE FLANGES

Double Bellows with a middle pipe. This type absorbs both axial and lateral movements. Other connection ends are available on request.

DOUBLE BELLOW WITH LOOSE FLANGES

Double Bellows with middle pipe made from Bellow material. This type absorbs both axial and lateral movements. Other connection ends are available on request.

In most projects, Belman customises the Expansion Joints for exhaust gas cleaning systems (scrubber). The Belman engineering page illustrates how we do this.

Engineering at Belman

MATERIALS

The media and the operating data of the type of process/scrubber determine the material requirements for the Expansion Joints. Usually, the Expansion Joints installed before the scrubber are made from stainless steel (AISI 316, AISI 321 or the like) and the Expansion Joints installed after the scrubber are made from higher alloyed chloride-resistant materials (254 SMO, 904L, Duplex or the like). The exhaust gas that is led into the scrubber is dry and heated; thus stainless steel is sufficient. When the media exits the scrubber, it has been cooled and washed; therefore, it can be wet/humid and may be acidic. For these reasons, the Expansion Joint is made from higher alloyed chloride-resistant materials, which reduce the risk of corrosion. Some scrubber constructions may encounter wash water back flow, which has to be considered in the choice of material for each Expansion Joint. Furthermore, Expansion Joints may have to be designed with inner sleeves due to high media velocities, and choice of material will be that of the Bellows. Choosing the right material from the start is therefore crucial for the long-term reliability of the system.

To sum up, the materials used are:

For the scrubber outlet typically:

1.4547 (254SMO)
1.4539 (904L)
Duplex
Superduplex
Alloy 59

For the scrubber inlet typically:

1.4571
1.4404
1.4410

Generally, Belman offers Expansion Joints in all types of materials on request.

MORE INFORMATION ON MATERIALS

Belman has seen many situations where vessels are struggling with unplanned stops due to leakages on the Expansion Joints in their scrubber systems. As the Expansion Joints are a wear part, the problems will show first here. Even a small leak can lead to significant issues such as reduced efficiency, unplanned downtime and non-compliance with emission requirements. To help clients, Belman has made a case study on material selection for scrubbers, as well as a video explaining this issue:

VIDEO ABOUT
MATERIAL ISSUES IN SCRUBBERS

How to select the correct material for the scrubber components

CASE STUDY ON
MATERIAL SELECTION FOR SCRUBBERS

INNER SLEEVES

Some scrubber Expansion Joints will – due to the flow velocity – require installation of an inner sleeve.

Why are inner sleeves important?

Expansion Joints are often introduced to the pipe system in order to introduce a flexible element for the compensation of thermal expansion, which makes them the stress relief of the system. In order to achieve the flexibility, the Expansion Joint is usually produced with a material thickness that is considerably less than that of the rest of the components. This however results in making the Expansion Joint vulnerable in some areas, which is why, in certain applications, it is necessary to mount a protective inner sleeve that can ensure the integrity of the Expansion Joint.

Why use inner sleeves on Scrubber Expansion Joints?

Inner sleeves are used for the internal protection of the Bellows and are used in several cases. For scrubber Expansion Joints, they serve the purpose of protecting the Expansion Bellows from high media velocity and possible particles in the media, resulting in erosion of the thin-walled Bellows.

How do the inner sleeves look? (Two types of inner sleeves)

If inner sleeves are needed for scrubber Expansion Joints, typically two types of inner sleeves are used:

Flared inner sleeve

This type is used when the scrubber Expansion Joint is designed with loose flanges.

Welded inner sleeve

This type is used when the scrubber Expansion Joint is designed with welded flanges or welding ends.

What is the inner sleeve made of?

The inner sleeve is typically made from the same material as the Bellows. As the inner sleeve will be in contact with the media, the material selected has to be resistant to the media.

How is it designed?

Whether an inner sleeve is required or not is determined by the media, the number of plies in the Bellows and the flow velocity. Information to Belman concerning flow velocity and type of media is very important when designing the Expansion Joints, as this forms the basis for the calculation of the inner sleeve thickness/type.

ADVANTAGES

Expansion Joints for different Exhaust Gas Cleaning (Scrubber) designs

No matter what the design, Belman excels in customizing the Expansion Joints for exhaust gas cleaning (scrubber) for the exact scrubber specification, as demonstrated in this passenger ship project. The Expansion Joints for exhaust gas cleaning (scrubber) are typically made from 1.4541 or 1.4404 (most often located at the inlet) and 254 SMO, duplex or super duplex. These materials are often specified when sea water is used for cooling (most often located at the outlet). The media and the operating criteria of the process/scrubber of course determines the material of the Expansion Joints for exhaust gas cleaning (scrubber). The exhaust gas that is fed into the scrubber is dry and heated and therefore AISI 316L is sufficient. However, when the media exits the scrubber, it has cooled and can be wet/humid with acidic properties. For these reasons, the Expansion Joints for exhaust gas cleaning (scrubber) are made from 254 SMO. Since the media in most situations has the possibility to run-back, the Expansion Joint is further equipped with an inner sleeve, also made from 254 SMO.

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, are strictly followed and implemented according to 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 are part of the Belman ISO 9001 quality management system approved by DNV.

ITP & Test

The 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 a third party based on the customer and classification requirements.

Destructive tests, such as life cycle test and burst test to validate the design, i.e., vessels and offshore platforms
Non-destructive tests, such as Visual testing, dye penetrant test, Radiography examination, Magnetic testing, ultrasonic testing, hardness testing and PMI for all applications
Proof tests, such as leak test with air, leak test with helium and formier gas, hydrostatic pressure test for all applications

EXPANSION JOINTS FOR EXHAUST GAS CLEANING SYSTEMS (SCRUBBER)

INSTALLED

WE HAVE ENGINEERED

EXPANSION JOINTS SINCE 1994

This enables us to find the optimum solution for your piping system.

IN CASE OF EMERGENCY

EXTRA SHORT DELIVERY TIME

Belman is known for helping clients in urgent need

A stop in the middle of the ocean due to failures on the system is critical, and so is extra waiting time in ports and yards for components. Belman’s fast track service is the solution for clients who have unplanned shutdowns, leaking Expansion Joints, part failures and other such problems. In such circumstances, clients need extraordinarily short delivery times, emergency service or additional assistance. If express delivery is required, we ensure the shortest possible delivery time on Expansion Joints. Our delivery response is in accordance with the customer’s delivery time needs and the complexity of the design. Get in touch to learn more about the shortest fast track delivery time Belman can provide for your project.

BELMAN FAST TRACK SERVICE

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