belman@belman.com
OIL & GAS
EXPANSION JOINTS
Expansion Joints for the Oil & Gas industry are used in a wide variety of applications. The many different applications within the Oil & Gas sector and the wide range of operating parameters set varying – and often very high – demands on the components installed, including Expansion Joints.
Applications:
- Upstream
(Offshore platforms, FPSO, oil rigs) - Midstream
(Crude oil storage terminals, tank farms, LNG/LPG vessels and
terminals, FSRU, gas processing plants, pumping stations etc.) - Downstream
(Oil refineries, Fluid Catalytic Cracking Units (FCCU), petrochemical plants, conversion units etc.) - Utilities & offsite plants
(Power generation plants, steam and boiler plants, water treatment and desalination plants, flare systems etc.) - Specialised facilities such as greener solutions
(Hydrogen, Carbon capture and storage)
Design expertise:
- High pressure
- Cryogenic temperatures
- High temperatures
- Special media compositions
- Special material requirements
- Special requirements for safety due to the nature of the applications
- Requirements for certificates, testing and 3rd party approval
Design range and scope of supply within Oil & Gas Expansion Joints
The capability design range for Belman and Oil & Gas Expansion Joints are:
DIMENSIONS:
DN 50 – DN 3000
(Belman range:
DN 25 – 12.000)
PRESSURE:
-1 barg to 215 barg
(Belman range:
From full vaccum up to
more than 250 barG if required)
TEMPERATURE:
-165°C to +700°C
(Belman range
-269°C to +1000°C)
MATERIALS:
All austenitic stainless steels (i.e. 1.4541, 1.4571, 1.4404, 1.4307 etc.), Duplex and Superduplex, Inconel 625 (2.4856), Incoloy 825 (2.4858), Hastelloy C-4 (2.4610), Alloy 59 (2.4605), Monel 400 (2.4360)
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
OIL & GAS EXPANSION JOINTS
CASE STORY
A returning client has ordered a 10-metre-long, Double-Hinged Expansion Joint with a nominal diameter of DN 1900. This new Flexible Joints will be installed in a different main feed circuit of the Northern European oil refinery, separate from the line where the client’s previously Belman-supplied 10-metre-long Expansion Joint is installed. The reordered 10-metre-long Flexible Joint can accommodate +/-400 lateral movement (range 800 mm) absorption. This represents a very large movement range for a DN 1900 Expansion Joint. To safely absorb these movements without overstretching or over-compressing the Bellows convolutions, a long built-in length of 10 metres was required, particularly to handle the lateral movements. Thus, the length of the Expansion Joint is determined by both the diameter and the required movement absorption. The lateral movements arise from ground settling, while the axial movements result from the temperature fluctuations. The hinges provide stability to the Expansion Joint construction and control the movement absorption.
CASE STORY
To help out a client in need, Belman reduced delivery time of 3 FCC Expansion Bellows to only 12 weeks. Belman designed and manufactured 3 refractory lined FCC Expansion Joints to suit the application at an oil refinery in the CIS. The Expansion Joints will be placed around the reactor and will carry mainly spent, regenerated, recirculation catalyst and flue gas. A short delivery time was essential for this project and Belman responded by producing all 3 units in an exceptionally short delivery time of 12 weeks. Belman made this possible by working around the clock and by choosing road transport to ensure the client received a fast, flexible and cost-efficient delivery. The rapid delivery was made without compromising on quality, documentation and project requirements.
REFERENCES
IOCL • Total Fina Elf • BP • Cepsa • OMV • Gunvor Petroleum • Shell • HPCL • Equinor (Statoil) • Idemitsu • Rosneft • Enap • Sobegi • TOR • NYRA Energy India • MOL • Chevron • Eni • Murco Petroleum Limited • Linde Ag • Qapco • Lukoil • Preem • Exxon Mobil • Total • PKN Orlen • Saudi Aramco • KNPZ • Vår Energi • Tatneft • PLAINS • Ceylon Petroluem • Aker BP • PCK •
Termo Petroleo • Rosenberg (Worley) • Repsol • Novatek • Valero • Azule Energy Angola • China National Petroleum Corporation (CNPC) • Ineos • National Refinery • Valero • GE Oil & Gas • ExxonMobil • Sinopec • SOCAR • Petrogal • NOV • Sonatrach • Ruhr Oel • Lukoil Neftochim Burgas • PETRONAS • PETKiM • ST1 •
TECHNICAL DESCRIPTION
TYPES & DESIGN
The Expansion Joint types and designs applied in the Oil & Gas sector cover both standard catalogue Expansion Joints as well as highly customised solutions designed for the exact application. However, Belman mainly sees the following types of Expansion Joints used within Oil & Gas applications:
- Untied Expansion Joints
- Universal Expansion Joints
- Tied Expansion Joints
- Hinged Expansion Joints
- Gimbal Expansion Joints
- Pressure Balanced Expansion Joints
- Elbow Expansion Joints
- Ring Reinforced Expansion Joints
- Clamshell Bellows
- FCC Expansion Joints
Customised Oil & Gas Expansion Joint solutions
As Expansion Joints are used in a wide variety of Oil & Gas applications and operate under a broad range of operating data, design conditions and medium compositions, the design, materials and features of the Expansion Joints can vary greatly from project to project. For some projects austenitic stainless steel is preferred, whereas for other projects high-alloy steels may be required due to marine environments or corrosive and/or abrasive media. Belman is highly specialised in selecting, engineering and producing the optimal custom solution for the client and the specific application in question.
MATERIALS
Expansion Joints for Oil & Gas applications are made from many different steel and metal types. Stainless steel and high-alloy steel types are generally used for both the Bellow(s), inner sleeve, flanges, middle pipe and welding ends. However in some situations, flanges, pipes etc. can be made from carbon steel such as A105, A106 etc. and then applied with a special coating. Belman can design and manufacture Expansion Joints for the Oil & Gas industry using:
- All austenitic stainless steels (i.e. 1.4541, 1.4571, 1.4404, 1.4307 etc.)
- Duplex and Superduplex
- Inconel 625 (2.4856)
- Incoloy 825 (2.4858)
- Hastelloy C-4 (2.4610)
- Alloy 59 (2.4605)
- Monel 400 (2.4360)
ADVANTAGES
- The correct Expansion Joint solution for the application
- Customised in all kinds of materials, even high alloys
- Cost-efficient solution for critical 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
TANK FARM BELLOWS
Tank Farm Bellows are specially designed as flexible connections between storage tanks and manifolds absorbing movements caused by tank settlement. Tank Farm Bellows are similar in appearance to standard Expansion Joints, but are specially engineered for this application, which requires a high degree of reliability throughout the entire service life of the storage tank.
Tank Farm Bellows provide:
• A reliable alternative to VJ couplings
• Reduced risk of unintended spills
• Absorption of large movements; both lateral and angular
• Extended service life
• Easy replacement due to flanged design, with customisable build-in length
• A 100 % guaranteed clear bore that is undisturbed by flow, enabled by a specially designed integrated inner sleeve
FCCU EXPANSION JOINTS
Expansion Joints built for use in fluid catalytic cracking (FCC) units are the most technically advanced designs among all existing Expansion Joint types, as they are exposed to: Highly aggressive and abrasive media, extremely high temperatures and large movements. FCC Expansion Joints are installed around the reactor and mainly convey spent and regenerated catalyst, recirculation catalyst and flue gas.
Product range
FCC Expansion Joints are available:
- As cold wall, hot wall and unlined
- In sizes up to DN 6000 (Belman range: DN 25-12,000)
- With leak monitoring systems and 2-ply testable Bellows
- With refractory lining
- With special hardware, such as manholes, sampling nozzles, pantographic linkages, control rods, slotted hinges, and protective Bellow covers.
- Designed and manufatured according to the required design code and/or standard specified by the client.
LNG/LPG EXPANSION JOINTS
FOR LIQUID GAS
Expansion Joints are installed in the following liquified gas applications:
- LPG/LNG carriers
- LNG-powered ships
- Special offshore units such as FPSO or FSRU
- Onshore production facilities
- Terminals
- and similar installations
Especially in applications such as: Pipelines to and from cargo tanks, pump outlet, cooling systems for LNG pipes, pipelines leading to regasification modules and MEG (Mono Ethylene Glycol) modules.
CLAMSHELL BELLOWS
FOR EASY REPAIR
Clamshell Bellows are two-piece Expansion Joints that are split in two halves longitudinally and then fitted into position and welded together on-site. Clamshell Bellows provide a very effective solution when a quick and unplanned replacement of the Bellows is needed. Clamshell Bellows are two-piece Expansion Joints that are welded together on-site. They can be retrofitted when the existing Bellows lose their ability to contain pressure. The purpose of Clamshell Bellows is to provide a very quick remedial solution with the least disruption to pipe system operations. The use of Clamshell Bellows invariably yields huge cost savings when compared with the cost of manufacturing and fitting a completely new Expansion Joint. They can be designed as oversized or same-sized and as both a temporary or permanent solution. Belman designs and manufactures this type of Bellows up to DN 12,000 in size, utilising all kinds of materials and in both round and rectangular shapes.
EXPANSION JOINT REFURBISHMENT
Instead of buying completely new Expansion Joints, options for refurbishment of Expansion Joints are worth considering. From a time perspective, cost perspective and environmental perspective, refurbishment often represents an attractive solution. Over the years Belman has carried out many refurbishment projects. On the basis of this experience Belman often promotes refurbishment as a good solution if the Expansion Joint contains heavy steel constructions in carbon steel or stainless steel. The parts that will be re-used are often sand-blasted and coated, making them appear as new. These re-used parts are then welded together with the new parts. New parts/replaced parts are: Bellow(s), inner sleeve(s), whereas re-used parts are: Welding ends and flanges, gimbals and hinges and other hardware.
The global Oil & Gas industry is increasingly moving towards greener, more sustainable operations in response to growing environmental concerns and regulatory pressures. Therefore, many Oil & Gas companies and operators are rethinking their approach to equipment maintenance and component lifecycle management. Rather than full replacement of worn or damaged components, there is a growing emphasis on repair, refurbishment and reuse. This extends equipment life, cuts waste and lowers the carbon footprint, thereby supporting the industry’s transition. For that reason, refurbishing its Expansion Joints was a very attractive solution for the client.
WE HAVE ENGINEERED
EXPANSION JOINTS SINCE 1994
This enables us to find you the optimum solution to your piping system.