Our customer was experiencing frequent failures of multi-layered fabric steering roll bellows on a hot dip continuous galvanizing line. Replacement of these bellows required a total shutdown of the process resulting in significant maintenance costs and lost production time.
Steering roll bellows on a hot dip continuous galvanizing line.
Multi-layered fabric bellows provide a flexible seal between the furnace wall and the bearing supports at each end of the rolls which must be capable of accommodating significant roll movement.
James Walker’s experienced engineering and design team produced design drawings for a novel bellows design incorporating modified steelwork and the application of new materials. A test rig was developed to simulate the application’s movements and new materials were sourced before prototype units were manufactured and tested to demonstrate performance. Close collaboration with the customer throughout this process resulted in an order placed on a further trial basis.
Our bellows have seen continuous service since early 2020, and have outlasted the previous supplier’s product several times over. Thermographic surveys have confirmed that our bellows are operating with a surface temperature 150°C below the previous solution, further increasing longevity. Following a total cost of ownership (TCO) analysis, annual savings in excess of €120,000 have been proven.
Our fabric expansion joints ensure efficient, safe and prolonged plant operation.
Installation, inspection and site surveys and are some of the services we can provide to support customers.
More than just manufacturing ‑ from initial design through to after‑sales support, consider James Walker an extension of your team.
Want to discuss your project, engineering or materials challenge expert to expert? Simply provide us with your contact details and a little information about the application you are working on, and one of our experts will contact you as soon as possible.