Tailor made
expansion joints
The Kompaflex group
Kompaflex is a Swiss company specialised in the design Kompaflex DMM [SK] is the third unit of the group, born from a
and production of metallic and fabric expansion joints for joint-venture with kompaflex ag. This subsidiary manufacture
critical applications. a range of fabric expansion joints.
Since its creation in 1981, Kompaflex ag has become a key There are in total more than 120 persons contributing to the
partner among large equipment manufacturers and end users production of expansion joints, across a combined manufac-
in the development of innovative and unique solutions. turing area of 10 acres.
Due to the increasing demand for metallic expansion joints,
kompaflex sro [CZ] was founded in 1995. This subsidiary is
entirely dependant of the Swiss office.
1983 1985 1986 1996 1997
Turbine expansion Pressure balanced Multi-ply rectangular DN3000 expansion joint DN4500 gas turbine
joints expansion joints expansion joint with no for a blast furnace featur- expansion joint
welding in the corners ing an Incoloy 825 inner
A WORLD INNOVATION layer
BBC Baden [CH] Sulzer [CH] Sidmar [B] Bremen Steel Works [D] Siemens [D]
(now Alstom) (now ArcelorMittal) (now ArcelorMittal)
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30 years of innovation
Kompaflex ag’s approach is to provide a reliable and satisfac- By desiging high precision and high performance products,
tory customer service. some has successfully been installed several years ago with-
out the need for replacement or repair.
Our innovative approache and expertise has enabled us to
manufacture customised expansion joints, thus meeting our Kompaflex ag is one of the rare manufacturers to be capable
customers’ most stringent needs whatever the given pressure, of offering unique designs.
temperature and media.
Multiply rectangular expansion
joints with no welding in the
corners
10 ACRES © all right reserved
www.kompaflex.ch, 9314 Steinebrunn, Switzerland, Tel. +41 71 414 71 00
TOTAL PRODUCTION AREA
Conical expansion joint on a gas turbine
1998 1998 2000 2009
Multi-ply & rectangular 299 ultra-high vacuum DN400 expansion joint with Rectangular expansion joint
DN 5000x3000mm expansion joints for the 600 Bar pressure resistance made of 3 bellows for large
expansion joints Wendelstein 7-X project for a blast furnace movements for a galvanising
line
Alstom Power [D] Max Planck Institute [D] Voest Alpine [A] Andritz Selas [F]
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Large diameters
A number of manufacturers offer large scale equipments to in- Expansion joints with diameter above 6 meter diameter are
crease the production and yields. Kompaflex has understood often best being manufactured directly on site for logistical
this constant search for performance by manufacturing diam- reasons.
eters up to 12 meter diameter.
Production of several DN7200 expansion joints directly on a Siemens construction site in Italy
«THANKS TO ITS GREAT FLEXIBILITY FROM THE OFFER TO THE ORDER EXECUTION, KOMPAFLEX HAS DEMONSTRATED
ITS CAPABILITY AS A KEY SUPPLIER. DURING A CRITICAL SITUATION, KOMPAFLEX IS ABLE TO MANUFACTURE LARGE
MULTI-PLY EXPANSION JOINTS DIRECTLY ON SITE. THIS ENABLES TO REDUCE THE TRANSPORT COSTS.»
M. Nalesso, GEA group
12 METERS
LARGEST DIAMETER EXPANSION
JOINT BY KOMPAFLEX AG
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Quick turnarounds
Because production shutdowns are not always scheduled,
Kompaflex ag is able to manufacture expansion joints rapidly,
thanks to a stockholding of a wide range of materials including
exotic alloys and a great production flexibility. Such availability
can minimise production losses.
24 HOURS
MANUFACTURING LEADTIME FOR
SOME EXPANSION JOINTS EVEN
MADE OF EXOTIC ALLOYS
DN5000 pressure balanced expansion joint manufactured and delivered on customer’s
site in less than 4 weeks
© all right reserved
www.kompaflex.ch, 9314 Steinebrunn, Switzerland, Tel. +41 71 414 71 00
DN6000 angular expansion joint for a cooling system
«KOMPAFLEX HAS PROVED TO BE A RELIABLE INTERNATIONAL PARTNER.
ITS TECHNICAL KNOWLEDGE, ITS PROMPT OFFERS INCLUDING DETAILED
DRAWINGS AS WELL AS ITS COST/PERFORMANCE RATIO GIVE KOMPAFLEX
DN4300 gas turbine expansion joint
THE STATUS OF A KEY SUPPLIER. TECHNICAL PROJECTS FEATURING
LARGE DIMENSIONS HAVE RUNNED SMOOTHLY AND ON SCHEDULE.»
U. Oster, SPX Cooling Systems
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Multi-ply expansion joints
Kompaflex ag masters the production of multi-ply expansion
joints. They feature the following advantages:
Reduced stresses
a better flexibility
a compact construction
a leak control device
a higher number of cycles
a lower spring rates
a higher lifetime
Rectangular expansion joints
When the use of rectangular expansion joints is necessary,
every manufacturer follows one of the following 4 corner
designs:
Apart from... Kompaflex ag
The highest mechanical stresses are concentrated in the cor-
ners and weldings become the weakest links of the whole
structure. These 4 corner designs are no exception.
Our expansion joints are manufactured in such a way that no
welding appears on the corners, only one appears on the lon-
gitunal side.
This manufacturing technique is still unique
Easier welding inspection
ONE WELDING SEAM No welding seams in the critical corner area
ONE WELDING ONLY IS REQUIRED ON OUR Higher flexibility / movements of bellows
RECTANGULAR EXPANSION JOINTS Longer life of expansion joint
Materials used Types of weldings achieved
• Austenitic metals • TIG
• Carbon metals • MIG / MAG
• Nickel and special alloys (Titanium, Inconel, Hastelloy, Monel) • Plasma / Micro Plasma
• Submerged Arc welding (SAW)
A wide range of materials is available in stock for immediate production start
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+
Standard expansion joints
PN 2.5 DN 50 - DN 7000
PN 64 DN 50 - DN 600
© all right reserved
www.kompaflex.ch, 9314 Steinebrunn, Switzerland, Tel. +41 71 414 71 00
Costumized.indd 2 05.06.12 09:53
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Engineering order from ITER fusion r
Design and FEM analysis for large rec
Engineering service
expansion joints
Our Engineering Department works closely with customers
and guide them to every step of projects.
Thanks to the use of the latest softwares, a number of services
can be performed aiming at achieving the optimal life of piping
systems and expansion joints.
Piping and auxiliary equipments layout and space
saving achiement
Selection of best suitable materials according to
uding matching
given applications
3D modelling and piping behaviour analyses
Efficiencies in movements and number of cycles
Rohr 2 calculat
ints exp
Finite Element analyses
Rohr 2 calculations including matc
expansion joints
Example of a stress free piping with the use of braced expansion joints.
on joint calculated
World first conical
Kompaflex ag has collaborated with the software developer
Sigma.
lysis with
The Rohr 2 software aims at designing piping systems and
fully integrates the expansion joints of kompaflex. Its use is
simplified thanks to the automatic calculations of parameters.
It also enables users to select the most suitable expansion
joint for a given application.
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Engineeri
gineering
eeringfrom
order orderITER
from ITER rf
fusion
Pressure balanced expansion joint with an Inconel 625 inner layer for a furnace
and
M FEM analysis
analysis forrect
for large lar
We are very often working on large scale projects and design-
ing unique systems, such as the ITER project.
The Croystat is made of 89 ports which give access to the in-
ner core. Some of these ports are as big as 4 x 3 meter.
expansion
expansion joints joints
Kompaflex ag has designed all the rectangular multiply expan-
sion joints of the Cryostat ports with the back-up of FEA analy-
© all right reserved
sis and replicating its thermal and seismic movements.
www.kompaflex.ch, 9314 Steinebrunn, Switzerland, Tel. +41 71 414 71 00
Development and modelling of expansion joints for the ITER Cryostat
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Quality is our trademark
MANUFACTURING STANDARDS AND CERTIFICATIONS
Kompaflex ag manufactures its expansion joints according to
the most stringent international standards.
Pressure Equipment Directive 97/23/EC (PED)
Modul H/H1
AD-2000 Merkblatt HP 0 and EN ISO 3834-2
CODAP
EJMA
GOST-R / Rostechnazdor
ASME U stamp
ISO 9001:2008
Traceability and documentation ensure the high quality of pro-
duction. Kompaflex ag can provide necessary documents to
the most complex projects including for nuclear applications.
Documents provided with every project
Expansion joint technical drawing
Technical description
Expansion joint Installation instruction
Documents provided on request
Test certificates
3.1 / 3.2 certificates
Welding qualifications
Inspection plan
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The quality assurance system has always been an important TESTS AND INSPECTIONS
part of Kompaflex ag since the ISO9001 certification has been Different types of tests can be performed to meet the indus-
obtained in 1988. tries’ stringest sealing needs, such as those in the vacuum or
nuclear sectors.
A parameterized 3-D CAD enables us to optimise expansion
joints according to the given customer specifications. Short hydraulic test pressure
production leadtimes and precise dimensions are obtained Colored dye penetrant
through the Computer Assisted Manufacturing (CAM). Helium leak test to 10-11 mbar l/s
Air and Nekal sealing test
X-rays
Ultrasonic
Destructive tests are also optional in our production site in
Switzerland.
Integral test in vacuum chamber
Helium leak test
© all right reserved
10-11 MBAR L/S
HELIUM LEAK TEST RATE ACHIEVABLE FOR
ULTRA-HIGH VACUUM APPLICATIONS
www.kompaflex.ch, 9314 Steinebrunn, Switzerland, Tel. +41 71 414 71 00
Mechanical fatigue test
Picture of polished cut image of a welding seam 720 bar test pressure
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Headquarter
Kompaflexstrasse 2
CH-9314 Steinebrunn
SCHWEIZ
Tel: +41 71 414 71 00
Fax: +41 71 414 71 10
info@kompaflex.ch
www.kompaflex.com
