A Metallic Bellow is a flexible, engineered component that absorbs mechanical movements and vibrations within a piping system. Typically made from materials like stainless steel or other high-grade metals, these bellows have a series of convoluted rings or folds that allow them to expand, contract and flex while maintaining strength and integrity. They are often integrated with pipelines via flanges on both ends, enabling easy attachment and a secure, leak-proof connection.
Metallic Bellows are essential for managing thermal expansion, pressure fluctuations and misalignment in piping systems, making them invaluable in industries such as oil and gas, power plants and chemical processing. The convolutes provide the necessary flexibility and resilience, while the flanges ensure a sturdy fit and compatibility with various pipeline setups. Functionally, these bellows absorb movement to prevent pipeline damage, extending their lifespan and maintaining operational safety.
We are Metallic Bellow manufacturers in India up to the following capacity :
Bellow I.D. – Upto 5000 X 4000 mm. (Rectangular)
Bellow I.D. – Upto 4000 X 4000 mm. (Square)
Bellow I.D. – Upto 3500 mm. (Circular / Round)
Working Temperature – Upto 1400°C.
Working Pressure – Upto 25 Kg. / Cm²
# Convolute materials : Stainless Steels – 202, 304, 304L, 310, 310L, 316, 316L, 321, 400 etc.
# Flange materials : Mild Steel, Stainless Steel, ASTM A105, SA516 Gr.70 & other Carbon Steel Grades.
# Optional accessories : Counter Flanges / Matching Flanges / Companion Flanges, Gaskets, Fasteners etc.
Metallic Bellows are specialized components used in various industries to handle pressure and temperature fluctuations. Their intricate design requires precise manufacturing steps to ensure durability and performance. Below is a detailed description of the manufacturing process for metallic bellows :
Material selection : Based on application requirements, the process begins by selecting stainless steel (SS) sheets of the appropriate grade, typically SS304, SS316 or similar materials.
# Cutting to size : The SS sheets are cut precisely to the required dimensions to maintain the inner diameter of the bellow. This step involves using cutting equipment such as laser cutters, shears or CNC machines for accuracy.
# Dimensional accuracy : The cut sheet size must match the design specifications to ensure the final product fits the intended application.
# Convolution formation : The cut SS sheet is formed into a series of folds or “convolutes.” This is achieved through a hydraulic press or mechanical rolling process that shapes the metal into a wave-like structure.
# Material and thickness considerations : The material thickness and number of convolutes are chosen based on the required pressure and temperature tolerances. For high-pressure applications, thicker sheets (e.g., 0.3mm to 1mm) are used, while for lower pressure, thinner sheets suffice.
# Heat treatment : Post-forming, the convolutes often undergo heat treatment to relieve internal stresses and ensure flexibility and structural integrity.
# Thickness control : The thickness of the convolutes is maintained to specific standards to withstand the operating pressure and temperature. This is monitored using precise measuring tools during and after forming.
# Material properties : The chosen material must offer high resistance to corrosion, fatigue, and temperature fluctuations. For extreme environments, special alloys like Inconel may be used.
● Flange manufacturing :
# Raw material selection : Flanges are manufactured using materials such as SS304, SS316 or other alloys based on corrosion and temperature resistance application requirements.
# Flange fabrication : The flanges are cut and machined to the required size and shape using CNC machines or lathes to ensure precision.
# Thickness consideration : Flange thickness is determined based on the application’s pressure rating. It typically ranges from 5mm to 25mm or more, depending on the pressure the bellow is designed to handle.
# Drilling holes : The number of holes and their placement in the flanges are customized based on the specific connection requirements of the application.
# Welding process : The convolutes are welded to the flanges on both sides using high-precision welding techniques such as TIG (Tungsten Inert Gas) welding. This process ensures a strong, leak-proof bond.
# Inspection : To ensure no defects, the welded joints are inspected using non-destructive testing (NDT) methods like ultrasonic or X-ray inspection.
# Leak testing : The entire assembly undergoes pressure and leak testing to validate its ability to operate under specified conditions without failure.
# Dimensional checks : The finished metallic bellows are measured to confirm they meet the specified dimensions and tolerances.
# Functional testing : A functional test may simulate working conditions, ensuring the bellow can handle pressure and temperature as required.
# Documentation : A quality certificate and compliance report detailing the materials used, test results, and specifications are prepared.
Used to absorb movement and vibration, protecting equipment from mechanical stress and ensuring reliable performance in high-temperature environments.
Essential for connecting machinery that experiences high heat and movement, helping to maintain the integrity of ducts and reducing the risk of damage from thermal expansion.
Employed to handle thermal expansion, contraction, and pressure changes, ensuring the safe and efficient transfer of fluids or gases.
Utilized to compensate for expansion and contraction due to temperature variations, ensuring the seamless operation of piping systems.
Critical for managing pipeline vibrations and movements, preventing leaks, and maintaining pressure stability in high-temperature and high-pressure applications.
Implemented to reduce vibration transmission, accommodate thermal movements, and ensure airtight connections, contributing to noise reduction and system longevity.
These are used to absorb expansion and contraction in duct systems, aiding in preventing environmental leaks and maintaining the efficiency of filtration units.
Applied to handle the expansion caused by heat in flue gas systems, maintaining structural integrity and preventing damage due to thermal fluctuations.
Helps to accommodate movements due to temperature changes and pressure variations, ensuring smooth flow and protecting joints from stress.
Integral for handling the transfer of fluids under high-pressure conditions, minimizing the risk of leaks and system failures due to temperature changes.
Used to manage the movement and stress in piping systems under varying temperatures and pressures, ensuring safe and uninterrupted operations.
An Axial Metallic Bellow is a flexible mechanical component that absorbs axial movement or expansion and contraction along its length. It consists of convolutions or folds made from metal, typically stainless steel, to provide high durability and flexibility.
Axial Metallic Bellows compensate for changes in length due to thermal expansion or contraction, mechanical vibrations, or other movements that can occur in pipelines, machinery, or systems. They help maintain system integrity by allowing movement without causing undue stress or damage to the connected components.
Axial type Metallic Bellows are commonly used in :
# Piping systems for industrial plants (e.g., power generation, petrochemical, and chemical processing).
# HVAC systems to absorb thermal expansion.
# Machinery and equipment that require vibration damping and flexibility.
# The aerospace and automotive sectors are used to manage temperature variations and structural movements.
# Marine and offshore applications to manage pressures and movements in harsh conditions.
# Flexibility : They provide flexibility to absorb axial movements without exerting excessive force on the connected components.
# Durability : Made from high-quality metals, they resist corrosion and wear, ensuring a long operational life.
# Temperature resistance : Capable of withstanding high and low temperatures, suitable for use in various extreme environments.
# Pressure Management : They can handle high internal pressures, making them effective for maintaining safe operations in pressurized systems.
# Vibration Reduction: Help minimize the transmission of mechanical vibrations, thus protecting sensitive equipment.
# Space Efficiency: Their compact design allows them to fit into limited spaces while providing adequate movement absorption.
A Universal Metallic Bellow is a flexible, corrugated component that absorbs mechanical and thermal movement in piping systems. It typically consists of two bellows joined by a center pipe, creating a structure accommodating lateral and axial movement. The bellow type is engineered to handle various industrial applications’ complex movement and expansion needs.
Universal-type Metallic Bellows are used for their ability to :
# Absorb Multi-Directional Movements : They can simultaneously handle axial (lengthwise), lateral (side-to-side), and angular movements.
# Reduce mechanical stress : These bellows help minimize the stress on piping systems and connected equipment due to thermal expansion, vibration, and mechanical movement.
# Compensate for Misalignment : They are ideal for systems with alignment issues, ensuring a flexible connection that maintains integrity.
# Enhance durability : They prolong the system’s lifespan by absorbing the movement and reducing stress on pipes and equipment.
Universal type Metallic Bellows are widely used in :
# Industrial Piping Systems : To manage movement due to temperature changes & pressure variations in power plants, refineries and chemical plants.
# HVAC Systems: To maintain flexibility in ductwork where expansion or contraction may occur.
# Marine and Aerospace: To accommodate complex movements in engine exhausts and other systems exposed to extreme conditions.
# Oil and Gas Pipelines : To protect pipes from stress due to shifting ground or fluctuating temperatures.
# Flexibility : They offer multi-directional movement capabilities, making them adaptable to various system requirements.
# Enhanced system safety : By absorbing vibrations and compensating for thermal expansion, they help prevent failures or ruptures.
# Reduced maintenance : The capacity to withstand extensive movement and reduce stress on piping means less frequent maintenance is needed.
# Customization : Universal bellows can be tailored for different sizes, pressure ratings, and material types to match specific application needs.
# Cost-Effective : Preventing damage to equipment and extending the system’s life helps reduce overall operational costs.
