When one of the world’s leading uranium producers faced an urgent need for a critical piping component at their Canadian mining operations, US Bellows delivered. Engineered and fabricated on an emergency rush basis, this 36” NPS Inline Pressure Balanced Expansion Joint is a testament to our team’s ability to respond fast without compromising quality.
The Application
The unit was designed to handle dry sulfur gas (SO₂/SO₃) — one of the most aggressively corrosive media encountered in industrial processing. The Pressure balanced expansion joint is placed between the converter and the boiler. Operating within a uranium conversion facility, the expansion joint serves to absorb thermal growth in the piping system while maintaining zero net pressure thrust loads on the connected converter — a critical equipment in the plant where chemical reaction of the contact process takes place.
The Design
Rated for 1,196°F at +/-14.5 PSIG (Full Vacuum) and 2.75” axial movement, the 36” unit features a pressure balanced configuration: three bellows of different diameters — two line and one balancing — working in tandem to cancel out pressure-induced forces so that no axial load is transmitted to the connected nozzles. The entire assembly, including bellows, liner, and structural hardware, was fabricated from 304H stainless steel, the high-carbon austenitic grade selected for its superior creep resistance at extreme temperatures. A full-bore internal liner protects the bellows from direct gas impingement and flow-induced vibration.
The expansion joint long seams of both the pipes, as well as the bellows were all 100% Radiography examined. Other pressure retaining areas were dye-penetrant examined. The complete expansion joint examined was leak-tested after completion.
Rapid Response, No Compromises
What makes this project stand out is the timeline. The request came in as an Emergency on Sunday, US Bellows responded within minutes of the request. From receipt of order to ship-ready unit, US Bellows compressed what is typically a multi-week fabrication cycle into an emergency turnaround completing fabrication on Thursday, only 4 days from the receipt of call on Sunday— mobilizing engineering, materials, and shop resources in parallel. For a mining and milling operation, every day of downtime carries significant operational impact. Our ability to execute under that kind of pressure, while meeting all design and quality requirements, reflects the depth of experience and flexibility that sets US Bellows apart.
US Bellows Capabilities
This project highlights several core strengths that we bring to every job:
- Emergency & rush fabrication — rapid response without sacrificing engineering and Quality
- Pressure balanced expansion joint design — eliminating thrust loads on sensitive equipment
- Corrosion-resistant materials expertise — selection and fabrication in stainless and high-alloy grades
- High-temperature applications — engineered for extreme thermal and process conditions
- Custom engineering — every unit designed to the specific demands of the application
US Bellows specializes in the design and manufacture of metal expansion joints for the most demanding industrial applications. Contact us to discuss your project.
