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Field Services: Installation & Maintenance
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Field Services: Installation & Maintenance

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This Webinar will focus on installation and maintenance guidelines and offer valuable tips on inspecting a wide variety of pipe supports and expansion joints in your piping system. We will cover ...

This Webinar will focus on installation and maintenance guidelines and offer valuable tips on inspecting a wide variety of pipe supports and expansion joints in your piping system. We will cover various pipe support applications and point out signs that indicate if a particular support needs replaced or adjusted. Obtain the knowledge you need to avoid the possibility of a potentially catastrophic situation.

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  • Condition of support components including: Variable springs Constant springs Restraint devices Hardware Pipe shoes Slide plates Expansion joints
  • Top Left: Replace – due to corrosion Bottom Left: Adjust – VERY crooked Middle: Travel stop still in support Top Right: No load indicator Bottom Right: Variable not supporting the load
  • LEFT PIC: Constant Support in Jamaica-Travel Pin is Rusted and Decayed
  • Which would include: Hydraulic snubbers Mechanical snubbers Sway struts Sway braces
  • ** replacement inspection performed relying on data sheets or drawings or a combination of the two for comparisons
  • ** Maintenance: not able to maintain them – maintenance not required up until point of replacement
  • ** Maintenance: not able to maintain them – maintenance not required up until point of replacement
  • Problem: Up thrust constants are not designed to absorb lateral movement.  The side to side movement of the pipe caused the bearings to become damaged and eventually fail.  Solution: Since the constants cannot be reinstalled to change the direction of the force caused by the movement, slide plates and new shafts must be installed. Piping Technology and Products, designed a shaft that had a washer on the outside surface of the bearings to reinforce the bearing and prevent it from coming apart.  To further reduce the force of friction, slide plates were added between the top of the load table and the bottom of the pipe support. 
  • Problem: Piping Technology & Products, Inc. received an emergency request through the website on Friday at 5:30 pm from a customer. The customer reported that the line anchors had failed, causing one of the 48” expansion joints to squirm. Resolution: Friday evening they sent PT&P the drawings and a purchase order for the job. On Saturday, the expansion joint was formed, and air freighted back to the customer on Sunday morning. The pipeline was back in operation on Sunday. PT&P suggested that tie rods be installed to prevent future squirming of the expansion joint.

Field Services: Installation & Maintenance Field Services: Installation & Maintenance Presentation Transcript

  • Attention All Attendees…
    • Welcome!
      • To listen to the audio portion:
      • 1.) Make sure your speakers are on and turned up.
      • OR
      • 2.) Dial: (1) 516-453-0014
        • (For countries other than the US, please refer to the list of numbers in your confirmation e-mail)
          • Access Code: (refer to your e-mail for your code)
      • Thank you for attending.
      • We will be starting at 10:00am CDT.
  • Piping Technology & Products, Inc. Field Service: Installation and Maintenance David Baker: David Baker: Presents
  • PT&P Structure
    • U.S. Bellows, INC.
    • Metallic Expansion Joints
    • Thin-wall, Thick-wall
    • Fabric Expansion Joints
    • Rectangular Expansion Joints
    • Slip-type
    • Member of EJMA
    • SWECO FAB, INC.
    • Pressure Vessels
    • Pig Launchers & Receivers
    • Spectacle/Line Blinds
    • Instrument Supports
    • ASME/Misc. Fabrication
    • ASME U-Stamp
    • Pipe Shields, INC.
    • Insulated Pipe Support
    • Commercial & Light industrial
    • Heavy Industrial - based on Mounted, Anchors
    • Pipe Riser Clamps
    • Fronek A/D E.
    • Hydraulic Snubbers
      • Short strut
      • Adjustable strut
    • Mechanical Snubbers
    • DynA/Damp Compensating Strut
    • ASME Nuclear Qualified
    • PIPING TECHNOLOGY & PRODUCTS, INC.
    • Engineered Pipe Supports
      • Variable, Constants, Big-tons
      • Vibration Control Devices – Snubbers, Sway Struts
      • Support Assembly Components – Clamps, misc.
      • hardware
      • Pre-insulated Pipe Supports – Cryogenic/cold & Hot
      • Applications
      • Fabricated Pipe Shoes, Guides & Anchors
    • Slide Bearing Plates
    • Anchor Bolts, Embed Plates
    • ICBO Certified, Member of MSS, SPED, APFA
  • Field Services
    • 􀂄 On-site Survey & Inspection
    • 􀂄 Installation & Maintenance
    • 􀂄 Problem Resolution
  • On-Site Survey & Inspection
    • General Inspection Includes Review of:
      • Piping irregularities
      • Apparent damage
      • Interferences
      • Condition of support components
    • Guidelines for On-Site Survey & Inspection
    • Inspections can be performed
      • During operation
      • During a shut-down
      • Or both
    • Frequency of inspections
    • Provide accessibility
    • Maintain results and develop a follow-up
    • inspection schedule
    On-Site Survey & Inspection
    • Designed to support a specified load:
      • weight of the pipe, commodity, flanges, valves, refractory & insulation through the install to operating thermal deflection cycle
    • Coiled springs are used to support the load and allow movement
    • Resistance of the coil to a load changes during compression, which is why these devices are called “variables”
    • Many different designs for variable supports and a particular nomenclature used to identify them
    On-Site Survey & Inspection – Variable Spring
  • On-Site Survey & Inspection – Variable Spring Type A Type B Type C Type D Type E Type F Type G
    • Visually inspect each spring hanger:
      • Search for signs of visual cracks, fractures, and corrosion of the spring casing and the following:
        • (1) beam attachment
        • (2) pin
        • (3) spring hanger attachment
        • (4) pipe clamp attachment
        • (5) weldless eye nut
        • (6) threaded rod
        • (9) spring coil
      • Check (7) turnbuckle (if present), lock nuts (8) and other threaded items to ensure they are secured and fastened
      • Compare the position of the (10) coil with the hot/cold load indicator and operating range of the spring
      • Check the mobility of the (11) load column
    On-Site Survey & Inspection – Variable Spring
    • Load Verification
      • Read load position
      • Determine load is acceptable/unacceptable
      • Possible causes of unacceptability
    On-Site Survey & Inspection – Variable Spring
    • Replacement Criteria
      • Signs of Excessive corrosion or fatigue
      • Rust Damage of entire unit
      • Modifications to operating conditions
    On-Site Survey & Inspection – Variable Spring Excessively corroded spring supports
    • Adjustment Criteria
      • After installation and plant startup, the spring load indicator should be at the hot position.
      • If not, the hanger should be adjusted to the hot/operating load position
    On-Site Survey & Inspection – Variable Spring
  • On-Site Survey & Inspection – Variable Spring
    • Field Examples
    • Used when large amounts of thermal deflections are involved (2” or more) and around sensitive rotating equipment where a load variation could be harmful.
    On-Site Survey & Inspection – Constant Spring
    • Horizontal Constants
    • Spring can aligns horizontally
    • Permits movements vertically
    On-Site Survey & Inspection – Constant Spring
    • Vertical Constants
    • Spring can aligns vertically
    • Permits movements vertically
    • Upthrust Constants
    • Permits vertical movement only
    • Spring can aligns vertically or horizontally
    • Visually inspect each Constant hanger:
      • Search for signs of visual cracks, fractures, and corrosion of the spring casing and the following:
        • (1) beam attachment
        • (2) pin
        • (3) constant hanger attachment
        • (4) pipe clamp attachment
        • (5) weldless eye nut
        • (6) threaded rod
        • (9) spring coil
        • (10) Check to see if Travel Stops are removed
      • Check (7) turnbuckle (if present), lock nuts (8) and other threaded items to ensure they are secured and fastened
      • Compare the position of the (10) coil with the hot/cold load indicator and operating range of the spring
      • Check the mobility of the (11) load column
    On-Site Survey & Inspection – Constant Spring Before and After Picture of Constant Load Support that Was Resized
  • On-Site Survey & Inspection – Constant Spring
    • Replacement Criteria:
      • Signs of excessive corrosion or fatigue
      • Rust damage of entire unit
      • Modifications to operating conditions
      • Consider internal components (cam mechanisms, bearings, etc.)
  • On-Site Survey & Inspection – Constant Spring
    • Adjustment Criteria
      • After installation and plant startup, the spring load indicator should be at the hot position.
      • If not, the hanger should be adjusted to the hot/operating load position
      • Consider the position of rod (swing angle also)
      • Consider adjustment of load (+/- 10%)
    • Field Examples
    On-Site Survey & Inspection – Constant Spring
    • Restraint Devices
      • Oppose Shock loadings
      • Brace pipe against sway
      • Guide or Restrain movement
    On-Site Survey & Inspection – Restraint Devices
  • On-Site Survey & Inspection – Restraint Devices
    • Hydraulic Snubber
      • Designed to allow thermal movement, but restrain impulsive or cyclic disturbance
      • Good for earthquakes, wind and continuous thrust due to safety valve "blow-off" or pipe rupture
    • Mechanical Snubber
      • Designed to prevent shock forces
      • Limits damaging motions by becoming (locking) a load carrying member
    On-Site Survey & Inspection – Restraint Devices
    • Sway Struts
      • Restrains movement in one direction while allowing movement in another direction
      • Effective under compressive or tensile forces
      • Allows for field adjustment
    On-Site Survey & Inspection – Restraint Devices
    • Sway Brace
      • recommended to reduce high frequency movement
      • guiding or restraining the movement of pipe resulting from thermal expansion
      • bracing a pipe line against sway
      • can be utilized in tension or compression
    On-Site Survey & Inspection – Restraint Devices
  • On-Site Survey & Inspection – Restraint Devices
    • Visually inspect each sway brace/strut/snubber:
      • End bracket
      • Pipe clamp attachment pins
      • Check for tight snug fit
      • Mark actual hot/cold deflections (snubbers)
      • Check for leakages (hydraulic snubbers)
        • Look at hardware, and site glass
        • If there is no oil visible in the site glass, add oil
        • Contact manufacturer
      • Check for lockups (mechanical snubbers)
      • Turnbuckle/locknuts
      • Threaded rod
      • Record findings
  • On-Site Survey & Inspection – Restraint Devices
    • Replacement Criteria
      • Visible signs of leakage including seal damage
      • Obvious signs of breakage
      • Excessive corrosion or rust damage
      • Modifications to design conditions
    • Adjustment Criteria
      • Only the C-C dimension (available length) can be adjusted
  • On-Site Survey & Inspection – Restraint Devices
    • Field Examples
    • Hardware: miscellaneous components required to complete a specified assembly
    On-Site Survey & Inspection – Hardware
  • On-Site Survey & Inspection – Hardware To allow adjustment of height or elevation: Job-fabricated Pipe Hanger Trapeze Hanger Double Bolt Pipe Clamp Adjustable Clevis Adjustable Rings
  • On-Site Survey & Inspection – Hardware
      • Inspection Criteria
        • Check for damaged support steel
        • Check for damaged hanger clamps
        • Bent hanger rods, hardware, etc.
        • Defective hanger hardware such as:
          • disengaged load pins
          • loose locknuts
          • missing retaining rings
          • cracked or inadequate welds
    • Replacement Criteria
      • Bent or broken components
      • Excessive corrosion or rust damage
      • Improperly sized components
    • Adjustment Criteria
      • Tighten or loosen rigid rod supports
      • Align components
      • Secure any lock nuts, cotter pins, etc.
    On-Site Survey & Inspection – Hardware No Lock Nut
  • On-Site Survey & Inspection – Hardware
    • Field Examples
    Clamp and Pipe Heavily Corroded Clevis Hanger Needs Replaced Bent Hanger Rod
    • Basic Pipe Shoe
      • Designed to support vertical loads
      • Clamp Type
        • used when welding to pipe is not allowed
      • Welded Type
        • used when excessive axial force is present
      • Guided Type and Sliding Type
    • Insulated Type
      • Designed to both insulate and support the pipe
    On-Site Survey & Inspection – Pipe Shoes Coldshoe for LNG Plant Clamp Type
    • Visually inspect each pipe shoe:
      • Check for corrosion
      • Check for structural integrity
      • Check for slippage
      • Check for insulation damage (pre-insulated supports)
      • Check for insulating properties (pre-insulated supports)
    On-Site Survey & Inspection – Pipe Shoes Welded Type Pipe Shoes
  • On-Site Survey & Inspection – Pipe Shoes
    • Field Examples
    • Types of Slide Plates - Offers a low coefficient of friction for sliding surfaces:
      • PTFE, 25% Glass Filled
        • Designed to allow objects to move (slide) freely along the supporting surface ambient temperature.
      • Graphite Slides
        • Designed to allow objects to move (slide) freely along the supporting surface at higher temperatures.
    On-Site Survey & Inspection – Slide Plates PTFE, 25% Glass Filled Graphite
  • On-Site Survey & Inspection – Slide Plates
      • PTFE, 25% Glass Filled and Stainless Steel
        • Designed to allow objects to move (slide) freely along the supporting surface ambient temperature while resisting oxidation.
      • Bronzphite ®
        • For high temp and heavy loads
      • Marinite ®
        • For extremely high temperatures
    Bronzphite ® Marinite ®
  • On-Site Survey & Inspection – Slide Plates
    • Visually inspect each slide plate:
      • Corrosion
      • Bonding
      • Damage
      • Cleanliness
      • Welds
      • Orientation
      • Gaps
      • Missing parts
    Damaged Slide Plate Slide Plate Not Attached Slide Plate Not Attached
    • Replacement Criteria
      • Excessive damage to sliding surfaces
      • Disbonding of sliding material
      • Improper sizing of slide plates
      • Improper application (regarding temp./load)
    On-Site Survey & Inspection – Slide Plates
  • On-Site Survey & Inspection – Expansion Joints
  • On-Site Survey & Inspection – Expansion Joints
    • Inspection Criteria
      • Develop inspection routine
      • Check movement
      • Look for signs of corrosion on the bellows
      • Review condition of threaded fasteners
      • Check flow direction and position
      • Correct application of expansion joint
      • Check for removal of shipping bars
    • Replacement Criteria
      • Excessive corrosion or fatigue
      • Cracks formed in the bellows
      • Leakage or loss of pressure
      • Excessive deformation
    • Adjustment Criteria
      • Unable to adjust
    On-Site Survey & Inspection – Expansion Joints
    • Installation & Maintenance
  • Installation/Maintenance – Variable Spring
    • Securely attach bottom of spring to the existing structure
    • Pass hanger rod through fabricated load column (type D & E only)
    • Attach other related hardware
    • After hydro-testing (if applicable) , then remove travel stops
    • Adjust the load indicator to desired setting (cold/hot load)
    • Load Adjustment
      • Spring hanger missing a name plate
      • Change in load is still within working range of spring support
      • Cost of field time & equipment required is less than the cost of new spring hanger
    • Maintenance Guidelines
      • Utilize the spring’s load column to set load point within the spring’s operating range
    Installation/Maintenance – Variable Spring
  • Installation/Maintenance – Variable/Constant Springs
    • Shutdown/Isolation Procedures
      • Step 1: Provide temporary support
      • Step 2: Re-install travel stops
      • Step 3: Secure them to housing
      • Step 4: Remove load from spring assembly
      • Step 5: Remove spring hanger assembly
    • Re-calibration:
      • Constant hanger missing a name plate
      • Load change is less than 10%
      • Spring is in good operating condition
      • Cost of field time & equipment required is less than the cost of new spring hanger
    Installation/Maintenance – Constant Spring
    • Snubbers
      • Confirm direction/magnitude of thermal motion
      • Verify snubber piston position
      • Position end brackets and/or clamp
      • Weld end brackets
      • Secure pipe clamp in position
      • Install snubber b/w end bracket point and clamp point
    • Sway Struts/Sway Braces
      • Confirm overall length required
      • Same guidelines pertain except for considering thermal movement
    Installation/Maintenance – Restraint Devices
    • Shutdown/Isolation Procedures
      • Lines/equipment must have a temporary support while repairs are made
    • Mark actual hot / cold deflections (snubbers)
    • Disconnect pins from rear bracket & clamp
    • Remove strut / snubber
    Installation/Maintenance – Restraint Devices Bent Sway Brace
  • Installation/Maintenance – Hardware
    • Lines/equipment must have a temporary support while repairs are made
    • Remove the component
    Installation Guidelines – Rod Hanger
    • Secure the hanger to the existing structure
    • Attach the connecting rod to the beam attachment and pipe clamp
    • Transfer the load by rotating the particular component
    Shutdown/Isolation Procedures
  • Shutdown/Isolation Procedures
    • Check for proper location (offset condition)
    • Install pipe shoe(s) by welding or bolting (proper bolt torque)
    • If required, install guides or stops
    Installation Guidelines – Pipe shoes Installation/Maintenance – Pipe Shoes
    • Lines/equipment must have a temporary support while repairs are made
    • Unbolt clamp-on type shoes
    • Remove weld b/w saddle plate and pipe on weld-on shoes
    • Remove insulation where applicable
    • Remove pipe shoe base
  • Shutdown/Isolation Procedures
    • Lines/equipment must have a temporary support while repairs are made
    • Gain close access to the slide plate(s)
    • Remove weld from backing plate and support structure
    • Remove the existing slide plate(s)
    Installation Guidelines – Slide plates
    • Surface must be smooth & clean prior to installation
    • Prepare mating surfaces to be welded
    • Align slide plate into position
    • Stitch weld into position following the drawing guidelines
    Installation/Maintenance – Slide Plates
    • Critical Phases During Install
    • Protect bellows during install to prevent damage
    • Confirm alignment
    • Pre-position bellows as required (regarding initial deflection)
    • Install anchors, guides, or supports
    • Weld/Bolt bellows in place
    • Remove any shipping banding devices
    • Maintenance
    • Periodic in-service inspections
    • Virtually maintenance free
    Installation/Maintenance – Expansion Joints Expansion Joint with Refurbished Bellows
  • Problem Resolution
  • Problem Resolution - Case #1 Problem: Bearing failure causing the upthrust constant to function incorrectly Resolution: Slide Plates and Shafts must be Installed
  • Problem Resolution - Case #2 Problem: Line anchors failed causing 48” joint to squirm Resolution: Fabricate new expansion joint fabricated, shipped back to customer and installed all within 2 days
    • Instructions for removal of travel stop pin
    • Turn turnbuckle clockwise if B-face of the travel stop pin is in contact with the travel stop keyhole (if the pin is jammed at the top of the hole)
    • Turn turnbuckle counterclockwise if A-face of the travel stop pin is in contact with the travel stop keyhole (if pin is jammed at bottom of hole)
    • When the pin is centered in the keyhole, travel stop pin can be removed
    Problem Resolution - Case #3 Constants on trapeze assembly Problem: Travel stops left in place on constant assembly Resolution:
  • Emergency Services
  • Inspection & Maintenance are ESSENTIAL
    • Leaking flanges
    • Continued pump & turbine problems related to bearings, seals and misalignment
    • Sagging lines and liquid trapped in low sections
    • Increased system stresses resulting in potential piping failures
    Consequences of NOT inspecting & maintaining pipe supports, hardware, & expansion joints:
  • Thank You For Attending… Our Field Services Webinar Please send any additional questions or inquiries to info@pipingtech.com We invite you to visit our Discussion Forum at www.pipingtech.com