Metal expansion joints (MEJ) also called compensators or metallic Bellows or metal bellows. An expansion joint/bellow element employed in a piping system is an assembly of generally more than one convolute in series with the shape of the convolution designed to withstand the internal pressures, Thermal expansion, mechanical vibrations of pumps, draft fans, compressors, turbines, motors, vessels and other plant components, but flexible enough to accept axial, lateral, and angular deflections. They consist of one or more metal bellows. Metal expansion joints have to be designed according to rules laid out by EJMA (expansion joint manufacturing association).For Fabric & Rubber expansion joints there are guidelines and a state-of-the-art description by FSA (fluid sealing association). Expansion joints are differentiated according to the three basic types of movement: axial, angular and lateral expansion joints. The central component of each expansion joint is the metal bellows. Due to its shape and thin wall, acts like a spring. The metal bellows however has to meet the following basic criteria to qualify for its use as an expansion element.

It must :
• Withstand the operating and test conditions (pressure, temperature).
• Ensure corrosion resistance.
• Provide sufficient flexibility for the purpose.
• Include sufficient squirm stability.

MOVEMENTS & SPRING RATES:

There are four basic movements that can be applied to a metal bellows. These are Axial, Lateral, Angular and Tensional. Respective spring rates are - Axial spring rate, Lateral spring rate, Angular spring rate. The spring rate of a metal bellows is entirely dependent on metal bellows geometry and material properties.

AXIAL MOVEMENT (+/? MM):

Axial movement is the change in dimensional length of the metal bellows from its free length in a direction parallel to its longitudinal axis. Compression is always expressed as negative (?) and extension as positive (+). The units for axial spring rates displayed in N/mm.

LATERAL MOVEMENT (+/? MM):

This relative displacement of the two ends of an Expansion Joint perpendicular to its longitudinal axis. This has been referred to as lateral offset, lateral movement, parallel misalignment, direct shear or transverse movement.

ANGULAR MOVEMENT (+/? DEGREES):

This displacement of the longitudinal axis of the Expansion Joint from its initial straight line position into a circular arc.

TYPES OF EXPANSION JOINTS:

• • Axial Expansion Joint
• • Lateral Expansion Joint
• • Hinge Expansion Joint
• • Gimbal Expansion Joint
• • Inline Pressure Balanced Expansion Joint
• • Elbow Pressure Balanced Expansion Joint
• • Externally Pressurized Expansion joint
• • Two ply testable bellow
• • Rectangular Expansion Joint
• • Slip Type Expansion Joint

Bellow sealed valves are a new type of Industrial Process valves. These valves are popular due to the leakage free performance hence, called “Zero Leak Valves” or “Emission Free Valves”.

With the application of Bellow seals the gland packing is supplemented by a metallic Bellow cartridge. One end of the Bellow is connected to the valve bonnet and the other end to the stem. The bellow movement is in one plane as the stroke in the valve takes place. With no rotational movements involved the fluid gets sealed to a very high degree. The fluid flows through the bottom part of the valve as per the stem movement takes place. Due to the bellow covering the stem the seal does not contact the stem at all. As the stem is the moving part in the valve it is the source of leakage due to the wear and tear of gland packing. Due to this shielding of the stem by the bellow the valve operated in a leak free zone.

The life cycle of the valve Bellows is largely dependent on the process of bellow manufacturing. At Pliant Bellows we manufacture them by hydroforming process. The properties achieved by the hydro forming process are far superior as compared to other process like, diaphragm welded bellows or mechanically drawn bellows. It is extremely important that the valve bellows have the mechanical and metallurgical properties for long cycle life of an bellow to avoid

For torque transmission in propulsion and positioning units:

Reliable, flexible and permanently backlash-free shaft coupling

SO IN SHORT ONE SHOULD USE THESE BELLOWS IN FOLLOWING CIRCUMSTANCES:

• • Excellent misalignment capability (compensation of shaft misalignments)
• • Minimum mass moment of inertia
• • High torsional rigidity
• • High availability due to flexible modular construction
• • Simple and fast attachment via one screw
• • Nominal torque: 16 up to 700 Nm


 

The torque on the clamping connection, which is transmitted via frictional locking, is dependent on the hub bore (shaft diameter). For permitted values and detailed information on size selection, please see the Product Catalogue. Metal bellows coupling guarantee a zero backlash torque transmission with extremely high torsional stiffness and a low moment of inertia. Different types of bellows, conical bushings and clamping hubs are available for different applications.

CHARACTERISTICS OF METAL BELLOWS COUPLINGS:

• • Torque range up to 700 Nm
• • high torsional stiffness
• • temperatures of up to 350°C
• • high speed
• • optional: stainless steel

Pliant Bellows is one of the top manufacturers of Metal Expansion Joints in India. We are the experts of Flexible Piping Systems. To provide the best quality pipe expansion joints, we have implemented the ISO-9001 certified design, manufacturing, and testing facility equipped with the latest technology and our metal expansion joints are designed strictly according to EJMA 2009 design guidelines.

We offer a broad range of flexible metal bellow expansion joints to cater significant share of industries with a wide variety of applications. Pliant Bellows believe that our strong faith in client feedback coupled with our relentless commitment towards the highest possible product quality standards makes our metallic bellows expansion joints such a success.

Behind this achievement is a team of dedicated engineers and visionaries with expertise in all type of metal expansion joints. Our team boasts of an extensive background in design, engineering and producing expansion joints for pipes, axial and lateral compensators, hoses and non-metallic expansion joints like fabric bellow and rubber expansion joints. Hence, specific application demands have and will never be a challenge for us at Pliant Bellows.

We provide bellow compensator asa Metal bellow expansion joints for a broad variety of applications, such as Expansion joint in heat exchangers which act as a thermal compensator, Valve bellows for bellow seal gate valve or bellow seal globe valve which is used for sealing application, etc. We also provide a broad range of Metallic Bellow Coupling for torque transmission applications with zero backlash and high torsional rigidity. Our customers have highly rated our bending beam bellow load cell used for weighing applications for its precision outputs.

Our commitment to quality of expansion joint, pipe expansion and metal bellows starts at the quotation stage. The products are produced using software designed by our skilled engineers using extensive field research and then tested in our in-house testing facilities before delivery. To reduce human based errors majority share of our work, right from costing to bellow design and calculations have been automated which are developed and maintained in-house by our engineers.

Being the top quality metal bellow expansion joints manufacturer in Pune, Maharashtra, it is our duty to keep a brand name that resonates with quality, state of the art technology and customer satisfaction. You can rest assured that all your flexible piping needs will be met with the finest products from Pliant Bellows, one of the top manufacturer of metal bellows in India.

SS bellow expansion joint setups are a creative alternate option for pipe and pipeline industries. These types of joints can easily be applied to the crude Oil & Gas, Paper & Pulps, Sugar plant, Chemical plant, Power sector and also Petrochemical sectors and also in several other fields. The most common application for a stainless steel single bellows axial expansion joint is to absorb axial movements of a straight pipe between primary anchors. This SS axial expansion joint should be placed near one anchor and guides should be utilized to ensure proper alignment and movement.

Metal expansion joints are beneficial portions of the pipeline system. We provide bellow expansion joint in a wide variety of materials ranging from Austenite series .i.e, SS 300 Series (SS304L, SS316L, SS321, etc.) to special alloys like Inconel, Hastelloy, Monel, etc. In pipelines expansion bellows are utilized to compensate length changes, which generally happen in pipelines from temperature modifications. In addition to this, they are capable of reading and absorbing vibrations generated by pumps, motor, compressors or wind turbines. Dependent upon the situation, axial and/or lateral pass movement, as well as angular movement, can be compensated. Metal expansion joints offer a cost effective choice of a pipeline system.

The reason for the best quality metallic bellow expansion joints produced by Pliant Bellows is our in-house developed Human Machine Interface (HMI) integrated Punch forming aka Mechanical Expander and Hydroforming Machine. We have developed this machines to control almost all the variables precisely. That is why we are compatible to produce miniature hydroformed metal bellows used for valve applications. Also, we provide metallic/ non-metallic hydroformed pressure switch bellow for instrumentation applications. Metal bellows are most often included in pipeline systems that link up pumps and vessels. The design of the convolutions in the metal bellow permits for increased axial, extensive, and angular movement. Due to the inclusion of state of the art technology along with the experienced engineers we are competent to produce metal bellow expansion joint with high fatigue life and with great resilience.

With our current competency level, we are confident to serve industries of almost all level, we request you to send your valuable inquiry to us at mktg@pliantbellows.com and our engineers will process the inquiry and will provide the quotation and necessary guidance if needed in no time. Always happy to serve you better.

When the angular movement is only in one plane hinge expansion joints or angular expansion joints are used. An angular expansion can be expressed when an expansion joint experience bending about its center which is the centerline and half way between the ends of metal bellows.

These types of expansion joints are used mostly in sets wherever piping direction changes. So you will find hinged expansion joints used at the locations where pipe bending occurs. Due to the hinged nature of this bellow only angular movement is allowed around the hinges. Since lateral movements too take place so there is a piping joint between these 2 bellows. The amount of lateral deflection a hinged expansion joint can accommodate for a given angular movement is directly proportional to the distance between them. To use a pair of hinged bellows effectively the distance between them should be made as large as possible. When only two hinge expansion joints are used as shown in the adjacent figure the piping perpendicular to the hinge segment must deflect to absorb the thermal expansion of the spool containing these angular expansion joints.

When the piping in a single plane system is not flexible enough to absorb the thermal expansion of the spool between the hinged joints a system of three hinged expansion joints may be used. In this system the combination of the three joints absorbs all the thermal expansion of the piping system and no deflection of the piping is observed. This system produces the lowest possible forces on the intermediate anchors and guides

If the thermal growth in the Piping System occurs in only one plane the use of this joint provides the most efficient solution to absorb the thermal deflections.

Lateral expansion joints refer to the direction perpendicular to the center line of the pipe expansion joint. Lateral deflection is also called as PARALLEL OFFSET and TRANSVERCE. The lateral expansion joint are also known as Tied Lateral expansion joints or Tied universal expansion joints.

Incase of absorbing large amount of Lateral deflections universal expansion joints 2 bellows are connected by a center spool (piece of pipe) and the tie rods are then attached on the outer ends for maximum deflection absorption. The length of center spool (center piece) plays a major role. In case the weight of center spool is significant it is supported by lugs. The benefit of the Tied universal expansion joint is it can be used in place where the piping joints are not in one place.

Lateral expansion joints are manufactured by using Stainless Steel as an expansion joint material to form flexible expansion bellows.

Lateral expansion joints are also called as Tied lateral expansion joints. These expansion joints are pipe expansion joints that hold mainly lateral actions - laterally along a segment of pipe. They are implemented with two or more tie rods or swivel tensions that restrict axial movements of the bellows.

The gimbal expansion joint is the most reliable expansion joint since it is capable of absorbing angular motion in all the planes. Although single gimbal expansion joint can be used in isolation the most common applications use a pair of gimbal expansion joints to absorb a complex multi-plane motion in a piping system. In adjacent figure Gimbal Expansion Joints are utilized in a pair to absorb the thermal expansion from the two horizontal piping arms. However note that the thermal growth of the vertical.

To avoid this deflection in the horizontal piping arms one or more hinged expansion joints can be installed in the horizontal arms of the piping system.

The speciality of the gimbal expansion joints is that they are fundamentally designed to perform the function of accepting angular movement in any plane. They are quite similar to hinged expansion joints except for the fact that unlike hinged expansion joints, gimbal expansion joints are not restricted to deflection in only one plane and allow bending and angulation in any plane. Gimbal expansion joints are generally preferred to be used in pairs so that they can hold, for instance, two sets of hooks pins, pivots, the shaft of each set perpendicular to the another.

Pliant Bellows is one such gimbal expansion joints supplier that manufactures its products following the guidelines postulated by the Expansion Joints Manufacturers Association (EJMA). The framework of all our commodities is accurate and precise designed to serve proper buoyancy.

Universal expansion joints is made up of 2 elements of bellows joined together by a common spool piece so it is also called as Double Bellows Expansion Joint or Universal Bellows.

A Universal Expansion Joint is generally used where more lateral movement is to be absorbed which is beyond the capacity of a single Axial Expansion Joint and when there is a limitation on the amount of lateral forces allowed by the connecting pipe system Universal expansion joints can take deflection in lateral, axial or angular movements.

Expansion joints are simply an assembly of bellows with other components to form a product that can contain movements caused by stress, thermal stress, and other seismic activities. They can be classified into multiple types based on their design, functions, and so on. Some of the common types are axial, lateral, hinged, gimbal, universal, elbow pressure balanced expansion joints and so on. Universal expansion joints are one of the most important and most used types of expansion joints.

The reason behind the widespread usage of universal expansion joints is that unlike a lot of the other types, these can contain movements in all 3 directions namely lateral, axial, and angular. Also known as a double bellow expansion joints, these are made with 2 bellows that are connected by a spool or pipe section. Another major advantage of using this over others is that large amounts of lateral deflection can be absorbed with this. If the capacity has to be increased, this can be done by increasing the length of the pipe section connecting the 2 bellows. In certain cases, tier rods may be attached to limit the axial expansion. If 2 tie rods are used, it can take in good lateral and angular expansion. By using more than 2, you can make the expansion joints to contain only lateral expansion.

Pressure switch bellows are designed to make electrical contact when a set pressure is reached. These switches can be designed to close or open on the pressure rising or falling. Many industries including automotive and diesel use these types of switches to maintain optimum system operation.

Diesel Generator Bellows:

We have capability to manufacture bellows for various diesel engines used in DG sets

Liquid filled temperature switches include a probe and a bellows element. The lamp is immersed in the process whose temperature is regulated. The bellows element detects the fluid pressure (liquid or gas) as the temperature rises in the process. The liquid in the sensor bulb responds to temperature fluctuations and increases the pressure in the bellows element as the temperature rises. An increase in the sensor bulb temperature compresses the bellows and moves the main spindle upward until the spring force and the bellows pressure are in equilibrium. This movement of the spindle is transmitted to the switch and causes depending on the setpoint of the temperature switch on or off operation.

Axial extension joints are the least difficult and most practical joint. It is utilized where little warm developments exist. The prime point of preference of pivotal extension metal bellows is, the bearing of the stream is bidirectional alongside their minimal size. Axial Expansion Joints are generally made in SS304L, SS316L, SS316Ti and SS321. If there should arise an occurrence of extraordinary prerequisites they can be made in Inconel and other nickel based combinations.

Axial expansion Joints should be installed co-axially with the pipes centerline. The purpose of this bellows is to compensate axial movements. With the existence of axial movements desired cyclic life can be achieved. If incase there exist other movements like angular or lateral this will affect the cyclic life of Bellows. Generally there expansion joints are used between straight pipes where movement is parallel to the centerline of pipe line.

SO IN SHORT ONE SHOULD USE THESE AXIAL EXPANSION JOINTS IN FOLLOWING CIRCUMSTANCES:

• • Movement compensation is in straight line.
• • Minute lateral/Angular movement can be adjusted but will affect the cyclic life of the expansion joint.
• • Bellows are not designed to absorb rotary movements.
• • Due to the line pressure between the piping systems numbers of expansion joints are required.
• • The best piping system is the once which is broken between intermediate stages with metal bellows at each stage

In case if the expansion/contraction rate is higher than the bellows capacity 2 Bellows with a center foot in between can be used. There 2 bellows are placed between the center of the pipes so that the axial movements from each ends of pipe can be absorbed by the respective bellows. One should note in case of cryogenic application the pipe expansion joint will be stretched as the piping system will contract.

The definition of an expansion joint, which is also known as a movement joint, is a joint application of the expansion or thermal movement of a part. Expansion joints, by the Association of Expansion Joint Manufacturers, Inc. (EJMA), meet the quality control standards established by the organization. EJMA, formed for the first time in 1955, is the standard setting organization for expansion boards and has been published by member manufacturers since 1958.

Expansion joints / Stainless Steel Bellows in QSK60 Engine: The Expansion Joint is a solution for the safety between the engine and the engine charged air line. It is connected between the engine charge airline through the engine cylinder head outlet to the silencer. We have successfully supplied these types of metal expansion joints to leading engine manufacturers internationally.

The Bellows Expansion Joints has an ability to compensate the vibrationsand the thermal movementsdeveloped in the system thus leading to the smooth working of the engine. Due to this Bellows/compensators installation the life and efficiency of the QSK60 Engine is enhanced considerably.

The Cummins Engine QSK60 Exhaust Bellows Part No: - KTA50, KTA38, 4080141, 3332253, 4080159 and PN3968643 is manufactured at World Class Standards by Pliant Bellows (Kwality products). The Cummins Engine QSK60 Exhaust Bellows are manufactured by Hydro forming process. The assembly is furthercircular seam welded using German seam welding technology.The Engine Exhaust Bellows are designed and validated as per Expansion JointManufacturers Association (10th edition)(EJMA 10th Edition)

Expansion joints / Stainless Steel Bellows in QSK60 Engine: The Expansion Joint is a solution for the safety between the engine and the engine charged air line. It is connected between the engine charge airline through the engine cylinder head outlet to the silencer. We have successfully supplied these types of metal expansion joints to leading engine manufacturers internationally.

The Bellows Expansion Joints has an ability to compensate the vibrationsand the thermal movementsdeveloped in the system thus leading to the smooth working of the engine. Due to this Bellows/compensators installation the life and efficiency of the QSK60 Engine is enhanced considerably.

The Cummins Engine QSK60 Exhaust Bellows Part No: - KTA50, KTA38, 4080141, 3332253, 4080159 and PN3968643 is manufactured at World Class Standards by Pliant Bellows (Kwality products). The Cummins Engine QSK60 Exhaust Bellows are manufactured by Hydro forming process. The assembly is furthercircular seam welded using German seam welding technology.The Engine Exhaust Bellows are designed and validated as per Expansion JointManufacturers Association (10th edition)(EJMA 10th Edition)

Expansion joints / Stainless Steel Bellows in QSK60 Engine: The Expansion Joint is a solution for the safety between the engine and the engine charged air line. It is connected between the engine charge airline through the engine cylinder head outlet to the silencer. We have successfully supplied these types of metal expansion joints to leading engine manufacturers internationally.

The Bellows Expansion Joints has an ability to compensate the vibrationsand the thermal movementsdeveloped in the system thus leading to the smooth working of the engine. Due to this Bellows/compensators installation the life and efficiency of the QSK60 Engine is enhanced considerably.

The Cummins Engine QSK60 Exhaust Bellows Part No: - KTA50, KTA38, 4080141, 3332253, 4080159 and PN3968643 is manufactured at World Class Standards by Pliant Bellows (Kwality products). The Cummins Engine QSK60 Exhaust Bellows are manufactured by Hydro forming process. The assembly is furthercircular seam welded using German seam welding technology.The Engine Exhaust Bellows are designed and validated as per Expansion JointManufacturers Association (10th edition)(EJMA 10th Edition)

Expansion joints / Stainless Steel Bellows in QSK60 Engine: The Expansion Joint is a solution for the safety between the engine and the engine charged air line. It is connected between the engine charge airline through the engine cylinder head outlet to the silencer. We have successfully supplied these types of metal expansion joints to leading engine manufacturers internationally.

The Bellows Expansion Joints has an ability to compensate the vibrationsand the thermal movementsdeveloped in the system thus leading to the smooth working of the engine. Due to this Bellows/compensators installation the life and efficiency of the QSK60 Engine is enhanced considerably.

The Cummins Engine QSK60 Exhaust Bellows Part No: - KTA50, KTA38, 4080141, 3332253, 4080159 and PN3968643 is manufactured at World Class Standards by Pliant Bellows (Kwality products). The Cummins Engine QSK60 Exhaust Bellows are manufactured by Hydro forming process. The assembly is furthercircular seam welded using German seam welding technology.The Engine Exhaust Bellows are designed and validated as per Expansion JointManufacturers Association (10th edition)(EJMA 10th Edition)

Expansion joints / Stainless Steel Bellows in QSK60 Engine: The Expansion Joint is a solution for the safety between the engine and the engine charged air line. It is connected between the engine charge airline through the engine cylinder head outlet to the silencer. We have successfully supplied these types of metal expansion joints to leading engine manufacturers internationally.

The Bellows Expansion Joints has an ability to compensate the vibrationsand the thermal movementsdeveloped in the system thus leading to the smooth working of the engine. Due to this Bellows/compensators installation the life and efficiency of the QSK60 Engine is enhanced considerably.

The Cummins Engine QSK60 Exhaust Bellows Part No: - KTA50, KTA38, 4080141, 3332253, 4080159 and PN3968643 is manufactured at World Class Standards by Pliant Bellows (Kwality products). The Cummins Engine QSK60 Exhaust Bellows are manufactured by Hydro forming process. The assembly is furthercircular seam welded using German seam welding technology.The Engine Exhaust Bellows are designed and validated as per Expansion JointManufacturers Association (10th edition)(EJMA 10th Edition)

An Elbow Pressure Balanced Expansion Joint is designed to absorb externally imposed axial movement without imposing pressure loading on the system. This is accomplished by using two bellows both at line pressure tied together and acting in opposite directions. It is used where pressure loading on piping or equipment is not acceptable.

To move the joint itself is not balanced. Both the flow bellows and balancing bellows must be compressed or elongated in operation and the combined axial spring force acts on the piping or equipment. Since the forces needed to move the bellows of these joints are of low magnitude these are usually not objectionable.

These elbow pressure balanced expansion joints are usually installed at change of direction. They may also be designed for in line operation. In case of single Elbow joints when it is subjected to both axial and lateral movements both the anchors at the end of the piping run and the one on the machine are intermediate anchors and only directional guiding is required. By proper design the guide directly above the equipment can be made to absorb the axial movement forces of the expansion joint without imposing these on the equipment. The only force imposed on the equipment is the force which is required to deflect the expansion joint.

Inline Pressure Balanced Expansion Joints are designed to absorb externally imposed axial movement without imposing pressure loading on the system. This is accomplished by using two bellows both at line pressure tied together and acting in opposite directions. It is used where pressure loading on the piping or equipment is not acceptable. While the joint balances out the pressure forces , the force required to move the joint itself is not balanced.

Both the flow bellows and balancing bellows are compressed or elongated in operation and the combined axial spring force acts on the piping or equipment. Since the forces need to move the bellows of the inline pressure balanced expansion joints are of low magnitude these are usually not objectionable. These joints are usually installed at change of direction. They may also be designed for in line operation. The complexity of the inline pressure balanced expansion joint makes it an expensive unit. Its use can be justified economically only in those cases where the problems created by the pressure loading would be even more expensive.

The inline pressure balanced bellows is a unique design which absorbs thermal motion while eliminating the pressure thrust loads on a piping system without a change in the direction of the piping consists of a constant volume device which is created by the addition of a balancing bellows whose cross sectional area is exactly twice the cross sectional area of the line or flow bellows. By proper cross linking the change in the volume of the line or flow bellows due to change in the length (i.e. due to compression or extension) can be made to cause an equal but opposite change in the volume of the balancing bellows, Thus since the volume changes are of equal value the pressure thrust forces that are normally present in the piping system containing bellows expansion joints are eliminated. Inline pressure balanced expansion joint is used where the location of the expansion joint prohibits or makes it very costly to install main anchors.

APPLICATIONS:

• For replacing pipe loops
• For reduced pumping energy