LOW SPRING RATES AND
LARGE MOVEMENT ABSORPTION
IN A 2.5 METRE-LONG
DN 2400
EXPANSION JOINT

For a copper mining complex in South America, Belman has designed and manufactured a large-sized DN 2400 Universal Expansion Joint with a built-in length of 2.5 metres. The Universal Expansion Joint is installed in a gas cleaning plant, more precisely in an air-gas heat exchanger, where it will absorb large axial movement and lateral movement in combination.

 

CLIENT ISSUE
A large DN 2400 Expansion Joint in the client’s mining complex had reached the end of its service life. As this pre-existing Expansion Joint had performed satisfactorily for many years, the client sought an identical replacement. Equipped with detailed specifications, drawings and requirements, the client needed an experienced manufacturer with the expertise to design and manufacture the large-sized Expansion Joint according to the latest EJMA standard.

 

BELMAN SOLUTION – low spring rates and large movement absorption in a 2.5 metre-long DN 2400 Expansion Joint
Belman engineered a 1:1 replacement solution based on the original design and client-supplied drawings. While maintaining the same design and functional requirements, the new design was updated to the latest version of EJMA. Additionally, Belman was able to reduce the spring rates compared to the original design, improving the Expansion Joint’s performance and minimising the loads on the heat exchanger. Achieving these low spring rates in a solution that also matched the original design was a major benefit for the client. The original design had been operating successfully for many years, and although the original design was not supplied by Belman, the team was committed to delivering a solution that met the client’s expectations. As in the previous design, the new Expansion Joint is designed with inner sleeves, as per the client’s request. Due to its weight of 1.3 tonnes and large dimensions, lifting lugs were incorporated into the design to ensure safe and efficient handling.

 

Large movements in combination and low spring rates
The Expansion Joint is designed to accommodate +/-100 mm axial movement and +/45 mm lateral movement in combination, which is a large range of movement for a DN 2400 Expansion Joint. In order to accommodate this movement absorption range safely without overstretching or over-compressing the Bellows’ convolutions, a long built-in length of 2.5 metres was required specifically to handle these lateral movements. This meant that the length of the Expansion Joint was determined by the diameter and the requested movement absorption. In large-diameter designs, length is a key factor in allowing sufficient flexibility.

 

Special bars for transport and installation
To safeguard the Expansion Joint during transport and installation, special transport and installation bars were included. These bars prevent unintentional compression or extension of the Bellows and enhance stability during handling. These bars are not for lifting – dedicated lifting lugs are used for that purpose, ensuring safe on-site operations.

 

Belman – proven experience in Expansion Joints for the mining industry
Belman has been supplying Expansion Joints to mining facilities worldwide since 1994. Having this vast experience enables us to design and manufacture reliable, efficient and cost-effective Expansion Joint solutions tailored specifically to the demands of the mining industry, regardless of application or client requirements.

Our expertise covers:

• Exact replacements (same-design Expansion Joints)
• Upgrades of existing designs to comply with the latest industry standards
• Completely new, custom-engineered solutions

We serve all types of mining operations involved in the extraction and production of copper, iron, lithium, gold, coal, molybdenum, silver and other metals and minerals. Belman’s Expansion Joints are installed across the full range of mining-related applications, from pipeline systems (such as tailing lines, pump stations, etc.) to processing facilities (including acid plants, foundries and more). Read more on our webpage: EXPANSION JOINTS FOR THE MINING INDUSTRY