UV PROTECTION COVERS ON
RUBBER COMPENSATORS
IN OUTDOOR MINING INSTALLATION

For a water infrastructure project in the Australian mining industry, Belman supplied 25 custom-engineered Rubber Expansion Joints ranging from DN 200 to DN 800 in various designs. The Expansion Joints are installed at different locations throughout the system to accommodate movements and thereby protect sensitive equipment. Due to the outdoor installation and exposure to strong sunlight, special metallic UV protection covers were required to improve the long-term durability and service life of the Rubber Bellows.

 

CLIENT ISSUE
On its water infrastructure project, the client needed to accommodate movements generated during operation. This meant that flexible connections were required and installed at several locations near various pumps and tanks, including intake pump outlets, the process pump’s inlet and outlet, and the brine pump’s inlet and outlet, among others. The client identified Rubber Expansion Joints as the preferred solution for the application. Due to a demanding project schedule, the client was looking for a supplier capable of delivering high-quality, custom-engineered Expansion Joints within a short delivery timeframe. Belman was selected based on its extensive experience, strong engineering capabilities, responsive project support and proven ability to deliver reliable solutions on time.

 

BELMAN SOLUTION

Rubber Compensators with special metal covers for protection against sunlight

Belman demonstrated its ability as a high-quality supplier with decades of experience in custom-engineered Expansion Joint solutions, on-time delivery and strong customer responsiveness. Based on the client’s specifications, Belman engineered the required Rubber Expansion Joints to fit the various installation points throughout the water infrastructure system. As several installation points are connected to sensitive equipment such as pumps, the Expansion Joints needed not only to accommodate movements, but also to minimise the transfer of pressure loads and reaction forces to the connected equipment. To meet these requirements, Belman engineered and supplied different Rubber Expansion Joint designs adapted to the specific operating conditions and movement requirements of each installation point.

• Three Pressure Balanced Expansion Joints
  Two DN 500 and one DN 700 Pressure Balanced Expansion Joint (weighing around 1.5 tonnes and 2.5 tonnes respectively) were specially engineered according to the client’s specifications. These Expansion Bellows accommodate both axial, lateral and angular movement while tie rods control the movement absorption. Pressure Balanced Rubber Expansion Joints are particularly suitable for installations connected to sensitive equipment such as pumps, as they minimise the transfer of pressure thrust and reaction forces to the connected equipment. In addition, this design reduces the complexity and size requirements of fix points and pipe guides, thereby improving the overall stability of the piping system.
• 22 Tied Expansion Joints
  The 22 Tied Rubber Expansion Joints were supplied in several different configurations adapted to the individual installation points and movement absorption requirements. All Expansion Joints were equipped with tie rods designed to absorb pressure reaction forces and control movement absorption. The placement and number of tie rods determine which types of movements the Expansion Joint can accommodate.

 

Metallic covers protect the Rubber Bellows from UV and sunlight exposure

In outdoor piping systems exposed to strong sunlight, Metallic Expansion Joints are often preferred over Rubber Expansion Joints due to the effects of UV radiation and elevated temperatures on rubber materials.
However, for this water infrastructure project, Rubber Expansion Joints were specified by the client due to the operational demands of the system. To ensure long-term durability in the harsh outdoor environment, the Rubber Expansion Joints were therefore supplied with metallic protective covers. Installed in direct sunlight, the Compensators are exposed to continuous UV radiation and elevated surface temperatures, where black-body temperatures can exceed 70°C. Over time, such conditions may accelerate ageing and reduce the flexibility of rubber materials. To protect against these conditions, metallic protective covers were supplied to shield the EPDM Rubber Bellows from UV radiation and elevated surface temperatures, thereby improving long-term durability and service life.

 

Materials and corrosion protection of the Rubber Expansion Joints

All of the supplied Rubber Expansion Joints were manufactured with EPDM Rubber Bellows and full-face rubber flanges to ensure reliable sealing performance. Furthermore, they were equipped with steel backing flanges adapted to the specific operating media and environmental conditions. For the Pressure Balanced Expansion Joints operating with seawater, the backing flanges and the protective covers were made from Duplex (1.4462) due to the aggressive and corrosive nature of seawater. Duplex stainless steel is known for its excellent corrosion resistance and suitability for demanding saltwater applications. For the Expansion Joints carrying brine and potable water, the backing flanges were manufactured from S235 and S355 steel protected with a C5 Marine corrosion protection coating system, according to the client’s requirements. The coating system consists of (1) zinc rich epoxy, (2) high-build epoxy MIO and (3) two-pack epoxy acrylic or aliphatic polyurethane in colour code RAL 7035 (N35 Light Grey). The metallic protective covers for the 22 Tied Expansion Joints were manufactured from material 1.4404 (AISI 316L). For additional corrosion protection, the tie bars on the Pressure Balanced Expansion Joints for seawater service were coated with a special Xylan® 1424 (green RAL), while the tie rods on the Tied Expansion Joints carrying brine and portable water were PTFE-coated.

 

Pressure test of the Rubber Bellows

Quality control and quality assurance were important elements of this project. All supplied Rubber Expansion Joints were CE-marked and manufactured according to PED 2014/68/EU. Non-destructive tests were conducted according to the inspection plan and included both Visual Testing (VT) and Pressure Testing (PT). In addition, full documentation was delivered to the client to ensure traceability, compliance and verification of the supplied Expansion Joints.

 

On-time delivery of the Rubber Expansion Joints

Time was crucial for the client, and Belman delivered all Expansion Joints on time and according to the agreed delivery schedule. As Belman’s location in Denmark is far from Australia, regular milestone progress reports were provided throughout the manufacturing process, allowing the client to closely monitor the project status and delivery progress. Due to the short delivery timeframe, all 25 Rubber Expansion Joints were transported by air freight. According to the client’s requirements, the Expansion Joints were securely packed in dedicated air freight boxes and divided into three larger transport boxes to ensure safe handling and delivery.

 

Belman – highly experienced in Rubber Expansion Joints

With extensive experience in Rubber Expansion Joints since 1994, Belman is the premier choice for high-quality Rubber Compensators for demanding industrial applications worldwide. Over the years, Belman has expertly supplied various applications with custom-engineered Rubber Expansion Joints worldwide including the mining sector, desalination plants, steel plants, chemical plants etc. An impressive track record assures clients the right solutions at the right cost, within the requested (and/or agreed) timeline. Belman is known for combining high engineering standards, responsive project support, comprehensive documentation and reliable on-time delivery.