Steel bellows-type compensators

Bellows-type compensators manufactured by the Elastic Elements Production Plant are intended to, among other things, compensate the linear expansion of pipelines (they take on the increase or decrease of the pipeline’s linear dimensions). Depending on the type and assembly conditions, a few various versions of compensators are manufactured by the Company i.e. with pipe endings (for welding - KR type) or with neck flanges (KF type), flat (KFP type), round, square etc. They can be also equipped with internal or external shields, compensation limiters and pretensioners. ZES also manufactures compensators with copper endings for copper installation systems (mainly applied in the building industry for central heating systems).

The application of steel bellows-type compensators in the heating industry, instead of solutions which have been applied so far, reduces costs related to the construction and operation of the heat supply system as well as facilitating the handling of the system.
Moreover the compensators can be used for:

  • the compensation of the vibrations of fuel pipes and aggregates and exhaust systems of combustion engines,
  • liquid fuel pipelines,
  • chimney ducts.
The compensators are designed and manufactured in compliance with EJMA principles, for the a/m parameters:
  • nominal pressure 0.25 to 1.6 MPa,
  • compensation from 16 to 140 mm, depending on dimensions,
  • working temperature up to 873 K.
The high quality and durability of compensators manufactured by the Elastic Elements Production Plant can be related to the fact that their main element - i.e. the elastic bellows is made of a multi-layer cold-rolled acid resistant steel. The method of hydraulic forming of the bellows also has a beneficial impact on the product quality.

The standard version of the compensators works in the conditions described in the enclosed catalogue cards. ZES can also manufacture compensators which will work in other physical conditions (various values of pressure, temperature and deflection), compensators made of other materials, customised compensators, compensators with external shields and with endings other than those shown in the catalogues.

NOTE:
We have developed instructions for the selection and assembly principles of bellows-type compensators designed for the compensation of linear thermal extensions of heat supply pipelines and others - we can provide our Customers with relevant technical advice.
Our compensators hold the Technical Approval of the Main Installation Techniques Research and Development Centre "INSTAL" in Warsaw.







Steel and non-ferrous-metal bellows

regardless of steel bellow-type comensators ZES manufactures a wide range of bellows, i.e. elastic ones, used for linear extension compensation and for the compensation of vibrations and extensions. These bellows, depending on their type, are designed for use as: the basic element of compensators, elements of measurement systems is automatization, as well as clutches, schields and elastic separators. They are manufactured as one- and multi-layer bellows from acid-resistant sheets of metal and from non-ferrous metals, like e.g. tin bronze, beryllium bronze, phosphorus bronze and brass. Apart from the bellows listed in the catalogue we can manufacture bellows of other measurements and from other materials.







Diaphragms and diaphragm kits

Diaphragms and diaphragm kits (diaphragm boxes) manufactured by ZES are mainly used for measuring, manometric and barometric flight instruments as well as other flight instruments such as:

  • pressure and speed indicators
  • altimeters
  • speedometers
  • variometers
  • parachute automated devices
Diaphragms are made of tin bronze, beryllium bronze, acid resistant steel and dispersion strengthened steel.







Non-ferrous metals and steel tubes

  • Non-ferrous seamless shot peened cold-rolled tubes. Shot peening excites mainly compressive stresses in the tubes which protects the tube's material from shrinkage porosity and the spread of the tube wall gauge is lower. This ensures a higher quality of the tubes in comparison to drawn tubes. The tubes are made of brass CuZn20, tin bronze CuSn6 and beryllium bronze.
  • Tubes made of coiled lap welded steel 1H18N9T.
  • Tubes made of coiled and longitudinal (butt) welded steel 1H18N9T.







Filters and springs

  • Metal filters are applied in the fuel systems of aircraft and tank engines and in the motorcar industry. Filtering elements are made from woven acid resistant steel meshes.
  • Among other things, spiral springs are used in measurement instruments and clock mechanisms. They are mainly made of beryllium bronze.
  • Flat springs are used in contact systems. They are made of beryllium bronze, 3H13 steel and dispersion strengthened steel.







Industrial services

A. Heat treatment of non-ferrous metals and acid resistant steel

  • Annealing of belts, strips and tubes made of CuZn20, CuSn6 in temp. 500°C in a CO2 protective atmosphere;
  • Stress relief annealing of bellows made of M80 and B6 in temp. 200 - 300°C;
  • Supersaturation of beryllium bronze belts and tubes in temp. 770°C in an ammonium atmosphere, slow cooling in water;
  • Dispersion strengthening of diaphragms, bellows, springs etc. made of beryllium bronze. Aging temperature 300 ÷ 360°C;
  • Recrystallization annealing and supersaturation of acid resistant steel in a vacuum furnace in temp. up to 1100°C, slow cooling by neutral gas. Dimensions of the vacuum furnace chamber: 550x300x250 mm.




B. Chemical treatment

  • Dimensional etching of bellows and diaphragms and other small parts made of brass and tin bronze and beryllium bronze;
  • Electropolishing of steel diaphragms and other small parts;
  • Chemical nickel plating of bellows.
    Note: dimensions of the plating tank: 350x350 mm;

C. Plastic working

  • Cutting of strips and sheets made of steel and non-ferrous metals:
    • 0.1÷0.5 mm cutting width up to 750 mm
    • 0.15÷0.5 mm cutting width up to 2000 mm
    • 0.5÷3.0 mm cutting width up to 1500 mm
  • Die shearing and stamping of steel and non-ferrous sheets:
    • Eccentric presses, pressure up to 25 T
    • Hydraulic presses, pressure up to 250 T
  • Rolling of high-alloy and non-ferrous strips and belts:
    • Width of strips and belts for rolling - max. 140 mm;
    • Gauge of the initial material for rolling:
      • strips 0.05 ÷ 0.8 mm,
      • belts 0.5 ÷ 2.5 mm.
    • Minimum gauge after rolling 0.04 mm;
    • Rolling tolerance - 0.005 mm
      Note: execution of heat treatment between operations can be arranged with the Customer




D. Recoiling of the strip

  • Width of recoiled strips max 250 mm;
  • Gauge of recoiled strips max 0.8 mm;
  • Coil internal diameter 400 ÷ 450 mm;
  • Coil weight max 800 kg.

E. Pressure welding

  • Welding on a capacitor discharge welder of steel and non-ferrous elements (joining of thin walled elements with thick walled elements is available):
    • Spot welding,
    • Circumferential welding,
  • Resistance welding of steels and bronzes:
    • Spot welding,
    • Seam welding,
    • Circumferential welding,

F. Fusion welding

  • TIG butt welding of tubes, external ø73 ÷ ø1000 mm, wall gauge 0.25 - 1.0 mm, tube length max. 900 mm;
  • TIG welding of elements - circumferential or longitudinal welding with a continuous weld, manual or on a semi-automatic machine, with or without additional material;
  • Microplasma welding - circumferential or longitudinal welding with a continuous weld, especially of thin-walled elements, gauge 0.1 mm and up.




G. Soldering

  • Soft soldering with stannic solders, including soldering of vacuum elements;
  • Hard soldering in vacuum blast furnace using silver, brass and copper;


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