References
Industries
we serve
References
High Vacuum / Research
Axial expansion joints for vacuum applications
Single-ply axial expansion joints DN 100 - DN 129. The bellows are used for Ultra high vacuum environment. The bellows have been specially designed for low spring rates with ply thicknesses of 0.15 and 0.2mm, welded and tested at kompaflex in a dedicated clean area.
Multi-ply expansion joints DN 50 – DN 109
Delivery of over 100 multi-ply expansion joints for a cryogenic magnet in Europe. Design, production, cleaning, testing and documentation of the expansion joints with DN 50 - DN 109.
Rectangular bellows to connect vacuum chambers
Rectangular expansion joints for connecting two vacuum chambers. The engineers at kompaflex have developed a tailor-made technical solution that is designed to meet the customer's specific requirements and fulfills all specifications:
Vacuum chamber
Single-ply vacuum chamber for a European research institute in the field of medical technology.
Single-ply axial expansion joints
Single-ply axial expansion joints DN 16 - DN 109. Design and fabrication according to DGRL / PED2014/68/EU.
Vacuum chamber / beam pipe
Application: Particle accelerator for medical application / cancer treatment. Welding of single Inconel X750 bellows to a curved chamber 1.5 m long forming the inner core of the accelerator.
Oval expansion joint 420 x 155 mm
Multi-ply expansion joint which is for a particle accelerator.
Rectangular expansion joint
Application: The expansion joint is used within the CERN LHC particle accelerator
Eliptical expansion joint 160 x 50 mm
Application: The expansion joint is used within the CERN LHC particle accelerator.
Expansion joints for cryogenic applications
Circular multi-ply expansion joints with different diameters for an accelerator from a leading research institute. Our technical experts have carried out various internal tests, for example a cryogenic shock test before the final helium leak test.
References
Nuclear / Fusion
Bellows / Expansion joints for the ITER fusion project
Delivery of over 90 expansion joints / bellows DN 96 for the ITER fusion project. 2-ply bellows with inter-ply connections for permanent leakage control.
Multi-ply reinforced rectangular bellows
First of a kind prototype for a multi-ply reinforced rectangular bellows for cryogenic application. Our engineering team have designed this tailored reinforced bellows for a fusion reactor in USA. The unique construction of this multi-ply rectangular reinforced bellows is that there are no welding seams in the corner areas. The initial design was validated with in-depth finite element analysis, followed by a 1:1 scale prototype. The prototype was successfully tested at 32 bar g
Expansion joints for a research institute
This expansion joint is a customized solution for an international research institute and the bellows will be installed in a nuclear fusion reactor.
Single-ply expansion joint DN 400
This tailor-made single-ply expansion joint has been specially manufactured for high vacuum application and will be installed in a fusion experimental reactor. The bellows was designed and tested in accordance with EN 14917 with a helium leakage rate of <1 x 10-9 mbar*l/sec.
Expansion joints for innovative future technologies
These single-ply expansion joints DN 200 are designed, manufactured and tested for a research institute, which is a spin-off of MIT's Plasma Science and Fusion Center. To meet the conditions in the high field tokamak, a helium leakage rate of <1 x 10-9 mbar*l/sec is needed.
Double-walled expansion joints
Two types of double-walled expansion joints (DN 150/250 and DN 250/350) with permanent leakage control, ISF connection and outside protective sleeve. Bellows are designed according to EN 14917 for ultra-high vacuum application for a nuclear fusion reactor for an international research institute.
Cryostat expansion joint DN 500
Application: Wendelstein 7-X fusion reactor
Technology: A expansion joint during the bake out phase, which allows a Helium Leakage Test of 10^-9mbar.
Lateral expansion joint DN 900
Lateral expansion joints for steam extraction pipe in a nuclear power plant. Design according to EN 13480 / PED Module H
Flange expansion joint 33 inch
Expansion joints and flanges with maximum permeability made entirely of 1.4429. Application in an American fusion reactor. Ultrasonic cleaning and electropolishing.
CF Flange expansion joints
Expansion joints and flanges with maximum permeability made of 1.4429 Used in an American fusion reactor. Ultrasonic cleaning and subsequent electropolishing.
References
Petrochemicals / Oil & Gas
FCC Double gimbal expansion joint
Project update for a European customer: Our latest endeavor is a double gimbal expansion joint designed to meet the highest standards for FCC applications.
Clamshell expansion joints FCC
Express delivery with clamshell expansion joints. Clamshell bellows are components designed and fabricated as two 180° segments. They are intended to be installed over the existing FCC Catalyst Regenerator Standpipe Expansion Joint on-site.
8 FCC Expansion Joints
Replacement of eight FCC Expansion Joints for a refinery in Europe. Five expansion joints are refractory lined. The expansion joints were extensively tested and inspected.
FCCU Expansion Joints
Replacement of three 2-ply FCCU Expansion Joints for a refinery located in the USA. kompaflex was responsible for designing, welding, and testing of the expansion joint. Refractory installation & final inspection with presence of end user happened at HSI.
Catalyst Regenerator Standpipe FCC Expansion Joint
One multi-ply FCC expansion joint DN 1200 with an assembly length of 5000 mm for a like-for-like replacement. The Catalyst Regenerator Standpipe Expansion Joint is equipped with Ceramic Fibre Blanket insulation, removable outer shroud, Pantographic Linkage, Control Rods and Purge Nozzles. The bellows are made of Inconel 625 LCF and fitted with a permanent leakage detection (inter-ply monitoring). The expansion joint is prepared for the refractory lining on site.
Double gimbal expansion joint
Double gimbal expansion joint for an oil refinery in the UK. Complete assembly 10 meters long whilst weighing 18.5 tonnes. 2-ply Inconel 625 LCF bellows incl. leakage control. Full stainless-steel body in 304H. Floating gimbal rings including ceramic insulation pillows.
Four refractory lined FCC expansion joints
Replacement of four multi-ply FCC stripper expansion joints for a European refinery. According to UOP specification, DGRL & PED. The expansion joints were extensively tested and inspected.
Lateral multi-ply expansion joint DN 1200
Lateral multi-ply expansion joint DN 1200 incl. hydrostatic pressure test according to ASME VIII Div. 1. Water pressure test according to ASME VIII Div. 1.
Expander load expansion joints DN 631
Four multi-ply expander load expansion joints DN 631 for a refinery in UK. The four expander load expansion joints had to match in-line pressure and compensate this force. This could be achieved as kompaflex versatile bellows manufacturing allows to manufacture to the exact diameter required. The pressure thrust force was verified with our test bench at presence of NoBo.
On-site installation of Clamshell expansion joints
Successful on-site installation of two Clamshell expansion joints kompaflex designed, fabricated and installed these over the existing FCCU Spent Catalyst Standpipe Expansion Joint. Our fully certified field specialist welded the 180° bellows segments on-site. The corrugated longitudinal weld of the Inconel 625 LCF bellows requires highest expertise and precision. The installed Clamshell were subsequently successfully tightness tested.
References
Heating & Cooling Technology
High pressure expansion joint DN 300 for heat exchanger
Multi-ply bellows from 1.4541 / AISI 321 with forged reinforcement rings allow a safe use of expansion joints for high pressure heat exchangers. Designed according to PED Modul G.
Expansion joint DN 1000 for heat exchanger
High pressure expansion joint with multi-ply bellows from 1.4404 / AISI 316L for a heat exchanger. According to PED Cat. IV Modul G. According to PED Cat. IV Module G.
Pressure balanced multi-ply expansion joint DN 600
Two pressure balanced expansion joints DN 600, which are welded into a compressor suction line at the European end customer. The multi-ply expansion joints, manufactured according to PED Module H, were tested internally by our experts with the hydrostatic pressure test and the helium leakage test with overpressure.
Three Hinge Expansion Joint System
A classical three hinge system consists of lateral and angular expansion joints. This system allows to compensate thermal movements from different pipe directions. Such tied expansion joints offer the advantage of not releasing any reaction forces on the system. The reaction force is taken care of within the restraining construction of the angular and lateral expansion joints.
References
Power Generation
Lateral expansion joints
Lateral expansion joints specifically designed and manufactured for use in a clean energy complex producing blue hydrogen and blue ammonia in USA. The complex will produce blue hydrogen as well as blue ammonia for global hydrogen markets such as the transportation and mobility sectors.
Expansion joints for Energy from Waste
Two gimbal multi-ply expansion joints DN 3200 and two lateral expansion joints DN 2235. One corner relief multi-ply expansion joint DN 3200, segmented version without T-piece. We provided the pipework constructor with the design drawings of the T-piece and the assembly plans to ensure that the end customer receives a tailored and complete module on site.
Expansion joint for gas turbine
Multi-ply expansion joint DN 4500 for a gas turbine. Thanks to the multi-layer bellows and the kompaflex expansion joint design including FEM calculation, the highest demands of a gas turbine can be met (temperature gradient, high temperatures, high movements, many cycles, vibrations, high flow velocity). kompaflex is the world leader in this application.
Corner relief expansion joint DN 1000
Corner relief expansion joints are capable to handle reaction force within the expansion joint without any fix points. Shown expansion joint is used in a Urea plant.
Multi-ply Rectangular expansion joint 1400 x 1400mm
Multi-ply rectangular bellows for smaller building length, larger movements and cycles.
Application: Thermal Power stations
Pressure balanced multi-ply axial expansion joint DN 600
The pressure balanced multi-ply axial expansion joints according to AD 2000 and CENELEC standards are used in a demanding environment. Tightness is important to ensure safe use in the gas-insulated switchgear. Thanks to kompaflex extensive equipment and test facilities, the Helium-Leakage test with overpressure could be carried out in house with our own experts.
Multi-ply oval expansion joint
Multi-ply oval expansion joints for a customer whose main focus is within the Fuel cell industry and is a leading player in marine applications. The challenge of this project was to provide a solution meeting their engineering and detailed requirement for their specially developed system.
Cross over Lateral Expansion Joint DN 1400
Lateral Expansion Joints movements in all planes. Placed in a cross over pipe of a steam turbine. kompaflex has in this application long-term experience of over 40 years with over 400 cross over pipe expansion joints in the field.
References
Steel Industry
Expansion joint DN 1458 / 2.4602 Hastelloy C22 / Alloy C22
Multi-ply universal expansion joint DN 1458 for a customer in Southeastern Europe, focused on the extraction and processing of mineral raw materials to end metal products.
Multi-ply expansion joints DN 1800
These two multi-ply expansion joints DN 1800 are designed and manufactured for a blast furnace for a steel mill in the UK. The bellows are made out of Incoloy 825 and are fitted with a bellows monitoring device to ensure highest reliability. The expansion joints are prepared for the refractory lining on site.
Rectangular multi-ply expansion joint
Used in an electroplating machine, where tightness all the time has to be given. Thanks to the multi-ply technology it is possible to increase the service life significantly.
The three multi-ply bellows of the rectangular expansion joint allow a very big axial movement of 450mm. In a small building length of only 940mm. Regardless of the big movement, 1000 full cycles are possible.
Multi-ply expansion joints DN 1200 – DN 3200
Four multi-ply expansion joints DN 1200 – DN 3200 designed and manufactured for a blast furnace. The inner ply of the bellows is made of Inconel 625 and Hastelloy C22. The bellows are fitted with a bellows monitoring device to ensure the highest reliability. The expansion joints were prepared for reftactory lining on site.
Expansion joint with bellows from 1.4539
Corner relief expansion joint DN 900 with multi-ply bellows from 1.4539 / alloy 904L for an increased corrosion resistance. Application in a steel mill.
High-pressure expansion joint DN 500
Thanks to massive reinforcement rings kompaflex expansion joints are able to withstand extremely high-pressure. The multi-ply bellows are made from Inconel 625 LCF. Application: Furnace
Pressure balanced expansion joint DN 1824
Pressure balanced expansion joint for a blast furnace pipe in a steel mill.
Multi-ply expansion joint, the inner layer are mad out of Inconel 625, as a protection of corrosion. Including a permanent leakage control of the first two layers of the bellows. Refractory lined to reduce the temperature on the expansion joint.
Angular expansion joint DN 1800
Customized angular expansion joint for a cowper stove. Multi-ply expansion joint, the inner layer are made from Inconel 625, as a protection of corrosion. Including a permanent leakage control of the first two layers of the bellows and refractory lined to reduce the temperature on the expansion joint.
Axial expansion joint DN 1810
Multi-ply expansion joint DN 1810 with six pneumatic cylinders and two proximity sensors for a steel mill in Asia. The axial expansion joint is designed for the under pressure -1 bar g.
Universal expansion joint DN 2400 blast furnace pipe
Flanged universal expansion joint for a blast furnace pipe of a steel mill. Multi-ply Inconel 625 bellows. Permanent leakage control.
References
Chemistry & Pharma
Pressure balanced / corner relief expansion joints
Four multi-ply pressure balanced / corner relief expansion joints for a European provider of nitrogen-based products in the fertilizer and industrial chemical market.
Hastelloy bellows C22 / Alloy C22
Client: Technology and system provider for the chemical industry. The shaft bellows are installed in stirring / mixing units for chemical processes.
Axial expansion joint DN 600 Hastelloy C22 / Alloy C22
Multi-ply axial expansion joint DN 600 for a manufacturer of pharmaceuticals based in Northern Europe.
Heat exchanger expansion joint DN 717
High-pressure expansion joint for a heat exchanger for the chemical industry.
DN 717 with a multi-ply expansion joint, made from Inconel 625 LCF. Design according to ASME VIII Div. II with reinforcement rings.
Single-ply axial expansion joint DN 1335
Single-ply axial expansion joint DN 1335.
Multi-ply axial expansion joint DN 400
Multi-ply expansion joint DN 400. The layers are made of different materials.
Multi-ply expansion joint DN 100 with PTFE inner pipe
Three bellows in series allow large axial movements for application in stirring / mixing units. The inner pipe is made of PTFE.
References
Marine
Prelude FLNG Project
The Technip and Samsung consortium has been awarded for the Prelude FLNG project in offshore Australia. It was the world’s first floating liquefied natural gas (FLNG) project of its kind. The single-ply expansion joint (not manufactured by kompaflex) installed between the compressors did not meet the requirements for the very high number of cycles. A suitable replacement was urgently needed and was critical to the project timeline. kompaflex was tasked with redesigning, manufacturing and delivering two metallic expansion joints in a record time of five weeks.