12 inch and 20 inch universal expansion joints delivered for oil and gas company in west africa
December 10, 2024

Delivering 12 inch and 20 inch Universal Expansion Joints for the Oil and Gas Company in West Africa

Client Overview

Our client, a major player in oil and petroleum production and storage facilities in West Africa, required reliable expansion joints for a terminal storage tank refurbishment project. The project included (1-off) 12 inch and (2-off) 20-inch universal expansion joints for their critical pipeline system. The project involved accommodating movement, pressure, and thermal expansion in challenging operational conditions. With a focus on durability and corrosion resistance, the client turned to Bellows Systems for a tailored solution.

Project Details

Bellows Systems designed, manufactured, and delivered 12-inch and 20-inch universal expansion joints for the client. These expansion joints were constructed from Alloy 825, a material known for its exceptional corrosion resistance, strength, and durability in demanding environments such as those encountered in the oil and petroleum industries.

The expansion joints also featured ,

  • 150# RFSO flanges , both welded
  • Bellows Liner – Incoloy 825 ( Alloy 825)
  • Bellows Cover – SS304 (ASTM A240)
  • Control Rods

The delivered expansion joints were designed to handle:

  • Axial, lateral, and angular movements to ensure flexibility and reduce stress on the pipeline system.
  • High-pressure and high-temperature environments, typical in oil and petroleum pipelines.
  • Corrosive conditions, leveraging the superior material properties of Alloy 825 to ensure long service life.

Why Inconel 825?

Inconel 825 was specifically chosen for this project due to its excellent resistance to corrosion in harsh environments, particularly those involving acidic and oxidizing agents often present in the oil and gas industry. Its robust properties make it ideal for ensuring pipeline safety and efficiency over time.

Key Benefits Delivered

  1. Enhanced Durability: The use of Inconel 825 ensures the expansion joints withstand corrosive elements, extending their operational life.
  2. Operational Reliability: Designed to handle complex movements and extreme conditions, the expansion joints optimize pipeline performance.
  3. Custom Engineering: Bellows Systems provided a tailored solution to meet the client’s unique operational requirements, ensuring seamless integration into the pipeline system.

Client Outcome

The same client previously successfully integrated universal expansion joints into their pipeline system, enhancing both the safety and efficiency of their operations. Impressed by the product quality and engineering expertise, the client awarded repeat order to Bellows Systems for delivering a reliable solution on time and meeting their specific needs.

About Bellows Systems

Bellows Systems has been a trusted partner in delivering high-performance metal bellows and expansion joints for over four decades. Our expertise in custom engineering and advanced material selection ensures that we consistently provide solutions that meet the demanding requirements of industries worldwide.

If you’re looking for a trusted partner for high-performance expansion joints, contact Bellows Systems today!

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Alpha MahatvarajDecember 10, 2024Expansion Joints, Oil and Gas, Universal Expansion Joints
3 Inch Single Tied Expansion Joints With Cover
October 16, 2024

Supplying 3-Inch Single Tied Expansion Joints for a New Peaker Power Plant in Texas

At Bellows Systems, we take pride in delivering high-quality, reliable solutions that meet the demanding needs of various industries. Recently, we had the opportunity to design, manufacture, and supply 100 expansion joints for a new Peaker Power Plant in Texas, ensuring efficient and safe operations for their closed-loop water cooling systems.

About the Project: The power plant required durable and flexible expansion joints to accommodate thermal expansion and vibrations within their cooling systems. Bellows Systems stepped in to deliver custom-engineered 3-inch single tied expansion joints, designed for optimal performance and longevity in high-pressure environments.

Key Features of the Expansion Joints:

  • 2-Ply Stainless Steel Bellows: Ensures flexibility, strength, and long life, even under demanding conditions.
  • Stainless Steel External Cover: Protects the bellows from external damage and environmental exposure, ensuring safe operation.
  • Stainless Steel Flow Liner: Provides smooth flow and reduces turbulence, minimizing wear and tear inside the joint.

    Reliable Solutions for Power Generation Our expansion joints are engineered to handle the rigorous requirements of power generation, including high-pressure and high-temperature environments. With this project, Bellows Systems continues its legacy of providing robust and efficient solutions for the power industry, ensuring that critical systems operate smoothly and safely.

    By choosing Bellows Systems, the Texas-based Peaker Power Plant has invested in high-performance components that ensure long-lasting durability, reliability, and safety. Impressed by the quality and performance of our products, they entrusted us with this new project as well. We are honored to continue our partnership and look forward to more opportunities to support their growth and success. 

    For more information on our expansion joints and other products, visit our website or contact our team.

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    Alpha MahatvarajOctober 16, 2024Expansion Joints, Power Generation
    Duct Expansion joint
    July 4, 2024

    Maintain System Integrity: Essential Duct Expansion Joints for Your HVAC

    What are duct expansion joints?

    Duct expansion joints are flexible connectors installed within HVAC systems to handle various challenges that could disrupt airflow and damage the ductwork. They act as silent guardians, ensuring the system’s efficiency and longevity.

    Why Use Duct Expansion Joints?

    • Protect Against Thermal Expansion: As temperatures fluctuate, ducts naturally expand and contract. Expansion joints absorb this movement, preventing stress on duct connections and potential leaks.
    • Isolate Vibration and Noise: Fans, blowers, and other equipment can introduce unwanted vibrations into the ductwork. Expansion joints act as shock absorbers, minimising noise transfer and protecting duct components from wear.
    • Accommodate Misalignment: During installation or due to building movement, duct sections may become slightly misaligned. Expansion joints provide flexibility, ensuring a proper seal and optimal airflow.
    • Safeguard Against Seismic Activity: In earthquake-prone areas, strategically placed expansion joints can absorb seismic movement, protecting your ductwork from significant damage.

    Types of Duct Expansion Joints:

    • Fabric Expansion Joints: These lightweight and cost-effective options are ideal for low-pressure applications. Constructed from flexible high strength composite fabrics like fiberglass textile with PTFE coating, they offer good thermal expansion absorption, resistance to corrosive conditions and good temperature resistance.
    • Metallic Expansion Joints: For high-pressure and high-temperature environments, metallic expansion joints with flexible metal bellows are the perfect choice. They are more durable than fabric joints, offering superior resistance to tears and punctures.
    • U-shaped Expansion Joints: A simple and economical solution for low-pressure and low-movement applications. These joints consist of a U-shaped duct section with flexible bends on either side.
    • Rectangular Expansion Joints: Specifically made for rectangular or square ducts, they can absorb thermal movements and vibration.

    Choosing the Right Duct Expansion Joint:

    The optimal expansion joint for your project depends on several factors:

      • Pressure Rating: Consider the maximum pressure your ductwork will handle.
      • Temperature Range: Ensure the joint can withstand the expected temperature fluctuations.
      • Movement Requirements: Determine the amount of expansion and contraction the joint needs to accommodate.
      • Space Constraints: Select a joint size that fits comfortably within the available space. 

    Bellows Systems offers a comprehensive selection of high-quality duct expansion joints to meet your specific needs. Our team of experts can assist you in choosing the right joint for your application, ensuring optimal performance and long-lasting system integrity.

    Contact us today to discuss your duct expansion joint requirements and experience the difference a seamless HVAC system can make.

     

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    Alpha MahatvarajJuly 4, 2024Other Products
    How to choose Materials for bellows
    May 10, 2024

    The Ultimate Guide to Selecting Stainless and High-Nickel Alloys for Corrosive Services​

    ​In industries that operate in corrosive environments, such as chemical processing, power generation, and oil and gas, the durability and reliability of metal bellows and expansion joints are crucial. These components must accommodate thermal expansion, vibrations, and other mechanical stresses while resisting corrosion. The choice between stainless steels and high-nickel alloys is vital for ensuring long-term functionality and safety. This article explores the considerations necessary for selecting the right materials for these applications.​

    Selecting Stainless and High-Nickel Alloys for Corrosive Services​

    Why Choose Bellows Systems?
    Hydroformed Metal Bellows

    Metal bellows and expansion joints are exposed to a variety of corrosive elements that can degrade materials through chemical reactions. These environments might include high concentrations of acids, bases, or salts, and can involve high temperatures and pressures. The primary corrosive factors to consider include the chemical concentration, temperature, presence of oxidizing or reducing agents, and mechanical stress factors like vibration and pressure fluctuations.

     

    ​

    Stainless Steels for Metal Bellows and Expansion Joints:​

    Stainless Steel Expansion Joints
    Stainless Steel Expansion Joints

    Stainless steels are favored for their corrosion resistance, mechanical properties, and cost-effectiveness. Types 304, 316, and 317 are commonly used in the fabrication of metal bellows and expansion joints:​

    • Type 304: An 18-8 austenitic stainless steel suitable for moderate corrosive environments. It is often chosen for its flexibility and fatigue resistance in lower temperature and concentration applications.​
    • Type 316: Known for its enhanced resistance to chloride ion corrosion, it is better suited for marine applications and environments with higher chloride levels. It is ideal for bellows that require higher strength and corrosion resistance.​
    • Type 317: Offers higher resistance than Type 316 and is suitable for more aggressive corrosive environments, often used in chemical processes involving stronger acids or higher temperatures.
    • ​Type 321: Similar to Type 304 but with added titanium to stabilize the alloy against chromium carbide formation. Type 321 is particularly valuable in applications where temperatures fluctuate sharply, such as in aircraft exhaust systems, industrial power generation systems or high temperature ducting. Its superior resistance to intergranular corrosion makes it ideal for bellows that experience both high temperatures and corrosive conditions.
    • Alloy 20: Known for its exceptional corrosion resistance to sulfuric acid and other aggressive environments, Alloy 20 (also known as Carpenter 20) is a nickel-chromium-molybdenum stainless steel alloy often used in applications involving sulfuric acid. Its robustness makes it an excellent choice for chemical processing equipment, including metal bellows and expansion joints that require high corrosion resistance and durability against acid attack.

    The selection of a particular grade of stainless steel depends on balancing performance, environmental conditions, and cost. Each type offers different levels of corrosion resistance, durability, and adaptability to environmental stresses.​

    High-Nickel Alloys for Extreme Conditions:

    Hydroformed Metal Bellows
    Hydroformed Metal Bellows

    In conditions where stainless steels might falter, high-nickel alloys provide superior performance. These alloys are especially effective in severe corrosive environments or in applications involving high temperatures:​

    • Monel (Nickel-Copper): Excellent for sea water and acidic conditions, making it suitable for offshore oil and gas applications where bellows are exposed to harsh marine environments.​
    • Inconel (Nickel-Chromium-Iron): Capable of withstanding extreme temperatures and pressures, ideal for power generation applications where high temperature resistance is crucial.​
    • Hastelloy (Nickel-Molybdenum-Chromium): Exceptional in resisting pitting and stress corrosion cracking, commonly used in chemical processing industries where strong acids are present.​

    These high-nickel alloys are selected for their ability to maintain structural integrity and corrosion resistance under extreme conditions, thereby extending the lifespan of bellows and joints.

    Case Studies and Practical Applications:​

    For instance, Hastelloy alloys have been employed effectively in expansion joints within sulfuric acid plants, where they resist the aggressive corrosion typically seen with fluctuating acid concentrations and temperatures. Monel has been utilized in refining processes to handle sour gas streams, where its resistance to sulfide stress cracking is critical.​

    Selecting the Right Alloy:​

    The selection process for metal bellows and expansion joints involves evaluating:​

    Environmental Conditions: Chemical nature, temperature, and mechanical stresses.​

    Material Properties: Fatigue strength, flexibility, corrosion resistance.​

    Cost and Availability: Initial cost vs. lifecycle cost, availability of materials.​

    Testing and real-world performance data are invaluable in making informed decisions. Simulated environment testing and historical performance in similar applications can guide the selection process.

    Conclusion:​

    Choosing the right material for metal bellows and expansion joints in corrosive environments is a complex decision with significant safety and financial implications. Stainless steels offer a balance of cost and performance for less severe environments, while high-nickel alloys are preferable for extreme conditions. Understanding the specific operational demands and conducting thorough material evaluations are essential for optimizing the durability and performance of these critical components. As technology advances, the development of new materials and improvement of existing ones will continue to enhance the capabilities of metal bellows and expansion joints in challenging industrial applications.

    Enquire Now
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    Alpha MahatvarajMay 10, 2024Bellows Materials
    BSI NADCAP CERTIFICATION
    January 18, 2024

    Bellows Systems’ Nadcap® Accreditation Makes Headlines in Aerospace News!

    Bellows Systems, Inc. is making waves in the aerospace industry as we proudly announce our recent Nadcap® accreditation for Resistance Seam Welding and metallographic welding examination. What makes this achievement even more exciting is that the news is buzzing about it

    In a recent press release covered by top-tier aerospace news outlets, we highlighted our commitment to continuous quality improvement and strict adherence to aerospace industry standards. Alpha Mahatvaraj, our CEO, expressed the significance of receiving Nadcap® accreditation, stating, “It demonstrates our ongoing commitment to continual improvement in quality. We remain focused on satisfying customer needs and delivering products in strict adherence to aerospace industry standards and specifications.”

    Jay Solomond, Executive Vice President and Chief Operating Officer at the Performance Review Institute, emphasized the global recognition of Nadcap® accreditation as a hallmark of quality. He praised Bellows Systems for achieving Nadcap® accreditation for Resistance Seam Welding and metallographic weld examination, acknowledging the hard work and dedication of our team.

    The coverage extends beyond the accolades to showcase our state-of-the-art purpose-built Resistance welding machines. These machines, capable of handling various diameters and materials, provide live feedback and post-weld reviews of numerous welding parameters, ensuring defect-free Aws D17.2 Class A, resistance welded joints.

    Not only has our welding capability gained recognition, but our metallography lab has also earned its stripes. Accredited and fully equipped, the lab conducts all necessary non-destructive and destructive testing to ensure Class A welds. The facility boasts new sectioning, grinding, polishing, and inspection equipment housed within an environmentally controlled room.

    About Nadcap®, created in 1990 by SAE International and administered by the Performance Review Institute®, this globally recognized accreditation showcases our commitment to quality, safety, and collaboration in the aerospace industry.

    As we celebrate this milestone, we invite you to read more about our Nadcap® accreditation in the featured articles, and explore how Bellows Systems continues to set new standards in aerospace quality.

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    Alpha MahatvarajJanuary 18, 2024News and Resources
    Ingersoll Rand KVS Engine Exhaust Manifold to Turbo Expansion Joint
    April 27, 2023

    Ingersoll Rand KVS Engine Exhaust Manifold to Turbo Expansion Joint

    At Bellows Systems, we take pride in designing and manufacturing high-quality metal bellows and expansion joints for a wide range of industries. Our exhaust service rated expansion joint designs for OEMs and OEM direct replacement have been in service for over 40 years.

    KVS expansion joints and assembly kits and are specifically designed to be direct replacements for Ingersoll Rand (IR) exhaust expansion joints. These expansion joints are drop-in replacements for OEM part numbers 1R20959B, 1R20959D, and are designed to fit seamlessly into the IR exhaust system.

    Bellows Systems manufactures direct replacement for IR exhaust expansion joints, drop in-liner and gaskets for OEM parts numbers,

    • Expansion Joints – 1R20959B,1R20959D
    • Sleeve – 1W40171
    • Gaskets – 1W47349, 1W40030
    Ingersoll Rand KVS Engine Exhaust Manifold to Turbo Expansion Joint

    Our premium KVS expansion joints offer dual floating flanges with formed Vanstone’s and significant improvement in bellows cycle life compared to the OEM parts.

    In addition to the KVS expansion joints, we also manufactured complete exhaust manifold kits for KVS engines. The drop-in liners and gaskets were made from high temperature corrosion resistant austenitic stainless steels and are designed to provide superior performance and reliability.

    At Bellows Systems, we understand the importance of keeping your equipment running reliably, which is why we offer premium replacement parts that are designed to meet or exceed OEM specifications. Our KVS expansion joints are built to last and are an ideal choice for reliable operations.

    To learn more about our premium KVS expansion joints and other replacement parts for Ingersoll Rand exhaust systems, visit our Exhaust Bellows page on our website.

    If you have any questions or would like to learn more about our products, please don’t hesitate to contact us.

    Enquire Now
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    Alpha MahatvarajApril 27, 2023Exhaust Manifolds, Exhaust Systems, Expansion Joints
    Seal bellows
    April 27, 2023

    Bellows Systems Delivers High-Performance Metal Bellows for Aerospace Sealing Application

    At Bellows Systems, we take pride in designing and manufacturing high-quality metal bellows and expansion joints for a wide range of industries. Recently, we delivered a batch of metal bellows that were specifically designed for aerospace sealing application.

    Aerospace Seal Bellows
    Aerospace Seal Bellows
    Aerospace Seal Bellows

    Our metal seal bellows are used in both static and dynamic sealing applications, and they are capable of withstanding operating pressures and temperatures that are beyond the capability of standard elastomeric seals. We can manufacture seal bellows in standard round, oval, and rectangular profiles. The standard material of construction can be stainless steels, high nickel alloys, copper alloys, titanium, and other metal alloys depending on the application.

    For this project, our design team customized the design of the bellows to meet the specific needs of the space industry customer. We considered key factors such as the seal bellows spring rate, overall stiffness, and high-temperature resistance to ensure that our metal bellows would perform optimally in the challenging environment of aerospace sealing applications.

    Our metal seal bellows are designed to provide superior performance and reliability under challenging service conditions ranging full vacuum and cryogenic temperatures to high pressure and temperatures.

     At Bellows Systems, we are committed to delivering high-quality metal bellows and expansion joints that meet the needs of our customers. Whether you need standard or customized solutions, our team of bellows and expansion joint experts are ready to work with you to design and manufacture the perfect product for your application.

    If you have any questions or would like to learn more about our metal bellows and expansion joints, please don’t hesitate to contact us.

    We look forward to hearing from you!

    Enquire Now
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    Alpha MahatvarajApril 27, 2023Expansion Joints, Metal Bellows
    What is a bellows liner? And when to use one?
    October 18, 2022

    What is a bellows liner? And when to use one?

    Bellows Liner is an internal sleeve that is used for the following cases,

    • To prevent flow induced resonant vibration of bellows due to high flow velocities
    • To reduce possibility of erosion from abrasive flow media 
    • To limit/ minimize the friction losses and create a smooth flow
    • To limit/ decrease the surface temperature of the bellows in high temperature applications. 

    Recommendations for proper design and use of a flow liner?

    • The liner material should either be same as the bellows material or suitable for the application.
    • When sizing a flow liner proper considerations must be given for the flow velocity, liner length and temperature of the flow media.
    •  When there is possibility for reverse flow, or bi-directional flow use of telescoping liner is recommended.
    • When used in applications with abrasive media use thicker liner material to prevent failure in the liner and exposing the thinner bellows material to erosion.
    • When lateral deflection or angular rotation is present, the liner should be designed with sufficient radial clearance to prevent interference with ID of the bellows through the entire movement range.
    • When bellows are installed vertically in the direction of the flow, proper drain holes shall be provided on the liner to drain fluid from being trapped.

    For our full range of bellows and exapnsions joint products

    Enquire Now
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    Alpha MahatvarajOctober 18, 2022Metal Bellows
    Marine Exhaust Expansion Joint
    September 13, 2022

    Marine Exhaust Expansion Joint

    All stainless steel metal Expansion Joint for Naval Vessels Main Propulsion Diesel Engine (MPDE). Bellows Systems originally designed and supplied the 36” expansion joints in 2007. The expansion joints have a 2 ply 321 stainless steel bellows element rated for 5000 cycles. 

    To learn more about our products for marine and shipping industry visit, Marine expansion joints

    Or visit, Exhaust system for engines

    Read More
    Alpha MahatvarajSeptember 13, 2022Expansion Joints, Marine and Shipping
    LSV-16 Exhaust Manifold
    September 13, 2022

    LSV-16 Exhaust Manifold

    Bellows Systems has delivered another new  built LSV-16 Exhaust Manifold. LSV-16 engine has an external water jacket cooled exhaust manifold with all stainless steel exhaust tubing and high performance Inconel bellows.

    To learn more about our line-up exhaust manifold products for Cooper Bessemer engines visit, Cooper Bessemer Engines Exhaust System

    We manufacture a complete line up of exhaust bellows and exhaust manifolds for large industrial engines. 

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    Alpha MahatvarajSeptember 13, 2022Exhaust Manifolds
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