Large Metallic Expansion Joint Upgrade for Hazardous Gas Service

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KLINGER Australia
Case Studies
Large Diameter Gimbal & Hinged Metallic Expansion Joint Upgrade

INDUSTRY:

Chemical

SOLUTION:

Gimbal Expansion Joints

Hinged Expansion Joints

OVERVIEW

KLINGER Australia successfully delivered a complex metallic expansion joint replacement project for a gas treatment and incineration facility, supporting the replacement of existing expansion joints operating in a high-temperature, toxic and corrosive gas service.

The project involved close collaboration between KLINGER teams, the engineering contractor and the end user across multiple countries throughout the proposal, design, manufacturing and delivery phases.

The Challenge

The facility required replacement of existing expansion joints that had experienced leakage with the application involved elevated temperatures, toxic and corrosive process gases.

Given the critical nature of the service, the customer required confidence that the replacement design would withstand process pressures, temperatures and movement requirements while addressing concerns experienced with the existing equipment.

In addition to the technical requirements, the project was operating under a demanding schedule.

Engineering Collaboration Across Multiple Countries

The project originated through KLINGER UK before being transferred to KLINGER Australia, which acted as the primary commercial and project coordination point throughout the project.

Throughout the proposal and design phases, KLINGER Australia worked closely with KLINGER Turkey, the engineering contractor and the end user to review technical requirements, clarify operating conditions and develop the most suitable expansion joint design.

During this process, detailed engineering documentation including general arrangement drawings and design calculation packages was provided for review and approval. These documents allowed the customer to verify the expansion joint configuration, movement characteristics and design suitability for the operating conditions.

Several design revisions were completed during the review process to accommodate project requirements and ensure alignment with site expectations.

Solving an Installation Challenge

The expansion joints were being installed into an existing plant with limited installation tolerances. During detailed engineering discussions, it was identified that provision would also be required for gasket installation between the mating flanges. As the expansion joints had been designed without axial movement capability, insufficient clearance was available to accommodate the gasket installation process.

To address this requirement, the restraint pin arrangement was modified to allow approximately 5 mm of controlled compression during installation. This design enhancement provided sufficient clearance for gasket installation while maintaining the intended operating performance of the expansion joint assembly.

The modification required additional engineering review and was incorporated through a formal project change order.

Large Diameter Custom Expansion Joint Solution

The final scope included multiple large metallic expansion joints manufactured from stainless steel 304.
Gimbal Expansion Joints
• Nominal size: DN1400
• Overall frame size: 1750 mm
• Overall length: 552 mm
Hinged Expansion Joints
• Nominal size: DN1400
• Overall frame size: 1818 mm
• Overall length: 573 mm

Quality Assurance

To ensure compliance with project requirements, the expansion joints underwent comprehensive inspection and testing throughout manufacture.

Visual and Dimensional Testing and Report
Pressure Testing
Penetrant Testing (PT)
Radiographic Testing (RT)

Comprehensive manufacturing documentation and quality records were provided.

Delivery and Outcome

With project schedules requiring rapid delivery, direct air freight was arranged from Turkey to the project site in Southeast Asia.
The project was successfully completed following final design approval, manufacture, inspection and release for shipment.
Throughout the project, KLINGER Australia acted as the primary commercial contact while coordinating closely with KLINGER Turkey and the customer to ensure timely communication, engineering support and project visibility.