Rubber expansion compensators – types and typical applications

Rubber expansion compensators are rubber expansion joints in a piping system that absorb the thermal expansion and contraction. Pipes will contract or expand as temperature changes. If not accommodated properly, this kind of movement will cause excessive stress or deformation and fail the system.

Rubber expansion compensators solve that problem by providing a movable connection relative to the installation around while sealing effectively and durably against leakage. Their ability to tolerate thermal expansion and contraction, lateral and angulation misalignment makes them an important component in HVAC, plumbing, power plants as well marine applications.

We will discuss the most common compositions / types of rubber expansion compensator, their primary applications / use, what to look out for when buying / using which one in your application and the inspection / maintenance / replacement do’s and do n’ts.

What are the most common rubber expansion joints, arranged by structural character? Mainly divided into: Arch type, bellow type & sleeve covers type. These three kinds structurally is rather diverse.

In large numbers of types the bellows style and cylindrical style rubber expansion compensator are used. It is composed of convolutions or shaped rings which compress and expand in axial direction – allowing linear movement within piping system.

These compensators are large oven thermal expansion and contracting enough to provide a solid seal in the joint. Tires can be made of synthetic or natural rubber – the former being less common in some racing tires today – and also come reinforced with metal cords or embedded plies, with different uses.

As the name implies, tied rubber expansion joints accommodate lateral or axial offsets in piping system.

The above joints were introduced for applications where pipes may move or be disconnected due to heat expansion/contraction, ground settlement etc. These ends are tied so movement is controlled during the operation without overstrain in any piping system.

Rubber expansion joints have metal reinforcement for applications with high pressures / temperatures / hostile operating conditions. Most of these compensators have rubber bellow or a sleeve with metal cords, rings finished. Or plies for reinforcement & toughness.

The metal reinforcement makes the compensator more robust to extreme operating conditions, reduces burst pressure damage and extends life expectancy. Originally used in automotive industries, these joints are present in different industries and applications including power generators, chemical processing plants and various industrial processes.

Other than above rubber expansion compensators are unrestricted, limited restriction and slip type which can be applied on movement requirements and operating condition.

Because rubber expansion compensators are flexible and can handle pipe expansion and contraction, they are found in many industries. Among the main uses are:

In residential as well as in commercial heating, ventilation and air conditioning (HVAC) and plumbing systems rubber expansion compensators are utilized routinely. As many of these systems have long piping runs where temperatures can vary dramatically, expansion joints are crucial to avoid catastrophic failure due to stress from this.

While cylindrical bellows style compensators are typical of HVAC systems, tied rubber extension joints would be more typical for plumbing applications where either angular offsets (elbows or lateral offsets) must be accommodated.

As mentioned previously the power generation industry uses rubber extension compensators extensively in the pipe systems of its fossil fuel/nuclear power plants to compensate thermal expansion in high temperature high pressure systems. For harsh environments like high temperatures or extreme pressures, reinforced rubber expansion joints can be used with metal cords or pliers.

Also chemical processing plants, petrochemical facilities and manufacturing facilities in general use rubber expansion compensators in a large number of their piping systems for safe and effective operation.

Rubber expansion compensators are an important part of ships, oil rig and other offshore structures to withstand that constant motion and vibration of marine and offshore structures. These compensators are corrosion resisting and can operate in saltwater conditions.

While tied rubber expansion joints serve for angular and latéral deflection requirements in marine applications, reinforced rubber compensators’are used in the case of high pressure/temperature offshore oil & gas installations.

Those mentioned industries ultimately depend on rubber expansion compensators so that their operations are safe and reliable with less chance of failures stopping operations.

The right product has to be selected to ensure rising bellows rubber extension compensator works safely and effectively for the required service life. There are lots of things to consider while selecting :

Temperature range: The rubber compensators are made according to temperature ranges that the rubber insideuilt-in them are used in.

Select a compensator which can cope with the temperatures the piping will experience in normal operation and in case of temperature spikes.

Rubber pressure compensators of each modification are specified to some extent in atmospheres for the pressure they can hold.

For such 1and1 power generation chemical processing etc we manufacture A higher pressure rating reinforced rubber compensators.

Unique characteristics of rubber expansion compensators like temperature range, pressure rating, movement capabilities and several others ratings and specifications are always furnished by the manufacturers.

For best performance of compensator accurate sizing according to piping system dimensions as well as movement demands is necessary.

Proper installation procedures should be observed (alignment, anchoring and support), in order to prevent compensator premature failure or excessive stresses on it.

Taking into consideration all of these factors together with advice from professionals or directly from manufacturers plant and facility operators can select the appropriate rubber expansion compensator to meet their application requirements for safety & reliability.

Rubber expansion compensators must be regularly inspected and maintained. You can prolong the life of these parts without spending a fortune on replacements or downtime with proper care and replacement when necessary.

*create an inspection plan based on the recommended schedule from your maker and operating parameters of your distributing piping system.

*Visual inspections also should be made for the detection of visible damage / wear / crack / deformation / etc on the rubber bellows / sleeves (if fitted).

Any leakage, misalignement or excessive movement which might indicate a problem with compensator should also be paid attention.

Rubber expansion compensator service life is variable according to the operating condition, material usage and maintenance.

most rubber compensator life expectancy is 5 to 10 years under typical operation (but may be much less or more depending on application).

Manufacturers usually provide service life expectations in terms of temperature, pressure and number of cycles.

Proper Storage 1and 1 Handle of Rubber CompENSATORS (Note: to avoid damages of rubber compensators prior to installation

Keep compensators in sheltered place away from direct sunlight and ozone elements that may affect the rubber over time.

* If replacement is necessary, safety recommendations for removal and installation from the manufacturer should be observed.

* Replacement must be done professionally with teaching by specialists who focus on the correct alignment / anchored / supporting of the new compensator.

In short, such inspection, maintenance and replacement procedures may reduce failure risk and increase service life of rubber expansion compensators for safe and reliable piping operation of a facility operator.

Rubber expansion compensators are indispensable for compensating thermal expansions/contractions in piping systems of various industries. Understand the types of compensators, their locations and criteria to be considered while selecting the best one.

Whether bellows style compensators for HVAC systems, rubber joints tied for plumbing, or metal reinforce expanders for industrial processes – the correct choice can release stress and avoid unnecessary deformation/elongation or failure of your piping.

Regular inspection, proper maintenance and timely appropriate measure of rubber expansion compensators are needed to give them longer service period without any problem on your piping structure. In case you operate your piping systems correctly and consult with professionals or the manufacturer of your system, you can likely do so for many years to come in case you follow best practices.