Field Services: Problem Resolution

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In this Webinar we explore the details of actual case studies focusing on various signs that indicate if a particular support needs replaced or adjusted. The presentation also covers projects that brought on new standard designs and custom designs for specific applications. And lastly, it includes valuable additions and procedures that extend the typical life span of a pipe support.

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  • Hello everyone, I would like to welcome you to our Webinar on Field Services: Problem Resoultion. The Webinar today is hosted by Piping Technology & Products. I am Jerry Godina and I will be your presenter. Also, if you have a question, please feel free to chat it to us during the presentation in the text box you see to the right of the presentation.
  • For those of you who are unfamiliar with PT&P, I want to quickly go over some background information. If you would like to know more, please visit our “About Us” section at pipingtech.com. Our parent company, Piping Technology & Products, Inc., also known as PT&P, is a member of MSS, SPED, and APFA In business since 1975, Piping Technology & Products, Inc. and its wholly owned subsidiaries (US Bellows, Sweco Fab, Pipe Shields, and Anchor Darling) offer a wide range of engineered products and services for various industries and applications. Our product line is extensive… From engineered pipe supports, expansion joints, pre-insulated pipe supports, and miscellaneous fabrication to various engineering and technical services, PT&P has decades of experience providing products and services for all your engineering and construction needs. The focus of today’s Webinar will be about the resolution of conflicts at the site. Foreseen could be accommodated during the design phase and carried through the manufacture OR those seen in operation which warranted retrofit at the site.
  • Case: It was necessary to increase the lifespan of an expansion joint for a coal-fired power plant. The solution was to design a self-cleaning slip-type expansion joint. Several special requirements where met by a combination of design features and material specifications including an aluminum bronze bearing sleeve. The inner barrel (which is directly in the vision of the operator) is uniquely plated to be corrosion resistant. This operator is using a load cell to measure the force required to move the joint. Pressure tests were used to check the six packing seals. This joint is to be installed in a horizontal position in the mid-span of 40" between guided supports. The design conditions are 12 " of movement, 650 ° F, and 50 PSI of internal pressure. http://www.pipingtech.com/news/arc_pw_1994/expjt1994_09.htm
  • 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.
  • Case: Limited use of graphite and temperature limits of PTFE, 25% Glass Filled for use in merchant plants Solution: Development of stainless steel encased Marinite to reduce heat gradient & withstand transients PTFE, 25% glass filled material was not protected from high temperatures Graphite was not strong enough to withstand water hammer in this application The Marinite insulator assembly allows the use of PTFE, 25% glass filled, as the sliding surface for lines with high operating temperatures and high dynamic loading - Maximum operating temperature for PTFE ≈ 325F –after which the glue could become dis-bonded - Using soli8d sheet of graphite proved unacceptable because of dynamic loading conditions Bronzphite® can also be used for high temperatures and high loads
  • 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. 
  • Insulated Supports Case… Case: Over 116 hot shoes for various sizes of large bore high energy steam lines failed. This caused the Energy Center to completely shut down due to safety concerns and the potential for pipe and/or equipment failure. The original vendor replaced the supports with the same type of supports, and they failed once again. PT&P was called in to survey the site and found that the type of pipe support used was not suited for the service conditions. http://www.pipingtech.com/news/enews/2005/090705.htm W:\\digital_camera\\Digital Album\\images\\Product Photos\\Competitor Products (field service survey and suggested replacement)
  • Because the elevations of all the piping were fixed, PT&P had to develop a pipe support design that would dissipate heat, in order to protect the PTFE, 25% glass filled slide plates from thermal damage. Natural Draft Air Cooling has several advantages over previous designs: 1. Since the insulation does not carry any mechanical load, it can be chosen solely on the basis of its thermal properties. In particular, cyclic loading, which has caused insulation failure, is not a problem. 2. The support provides effective restraint for all six possible components of loads, X, Y, Z-Rotational and Translational. In particular, axial and Torsional loads are readily accommodated. These represent difficulties for supports which rely on the insulation. 3. It is easily installed in the field and is attached to the pipe with a standard bolted pipe clamp. Thus, there is no field welding. The line temperatures ranged from 650°F to 1100°F. PT&P performed full EPC services and manufactured all of the supports for this project. Finite Element Analysis was also performed.
  • The top two pictures show the restoration of insulation after installation of new shoes The bottom two pictures show the steam lines after installation PT&P designed the solution needed for this dilemma and acquired a new patent for a pipe support with two clamps that are similar to the Figure 50 light two bolt pipe clamp. Each shoe is attached to a steel plate which is designed to carry the design load, and is shape optimized to minimize heat flow from the pipe.
  • Combination slide plate materials, including stainless steel and phosphorus bronze used to support vessels The carbon steel base plate will be securely anchored to a foundation Instead of welding, the lower slide plate will be affixed to the carbon steel base by countersunk attachment bolts The upper slide plate is fabricated from a phosphorus bronze plate with machined grooves on the underside The grooves allow lubrication between the contact surfaces of the upper and lower slide plates
  • The grease is replenished through the zert fitting pictured here The stainless steel is polished to achieve a low coefficient of friction Countersunk bolts are used to avoid interference The hole you see to the right of the slide plate is the access point for pouring the grout after installation
  • Field Services: Problem Resolution

    1. 1. Piping Technology & Products, Inc. presents… Field Service: Problem Resolution
    2. 2. David Baker Field Service Manager Piping Technology & Products, Inc.
    3. 3. U.S. Bellows, Inc.  Metallic Expansion Joints  Thin-Wall and Thick-Wall  Rectangular Expansion Joints  Fabric Expansion Joints  Slip-Type Expansion Joints 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 IAS Certified, Member of MSS, SPED, APFA Member of EJMA SWECO Fab, Inc.  Pressure Vessels  Pig Launchers/Receivers  Spectacle/Line Blinds  Instrument Supports  ASME/Misc. Fabrication ASME U-Stamp & R-Stamp Pipe Shields, Inc. Insulated Pipe Supports  Commercial & Light Industrial  Heavy Industrial – Base Mounted Types, Anchors  Pipe Riser Clamps ISO 9001-2000 Certified Fronek A/D Ent., Inc.  Hydraulic Snubbers - Short & Adjustable Strut  Mechanical Snubbers  dynA/Damp Compensating Strut ASME Nuclear Certified PT&P Structure
    4. 4. History
    5. 5. <ul><li>Houston, Texas, USA </li></ul><ul><li>450,000 square feet covered shop space </li></ul><ul><li>35 acre property </li></ul><ul><li>Located near Port of Houston for convenient shipping around the world </li></ul>Facility
    6. 6. Case #1 – Design Custom Supports for Special Requirements Problem: Standard support designs unable to meet travel, load, and spatial requirements Resolution: Develop custom spring assemblies with non-standard components <ul><li>Dimensions: 20&quot; x 20&quot; x 8 7/16&quot; </li></ul><ul><li>Load: 7839 lb. </li></ul><ul><li>Movement: 0.48&quot; Upward </li></ul><ul><li>Spring Rate: 1500 lb./in. </li></ul><ul><li>Load: 50,022 lb. </li></ul><ul><li>Total Travel: 4 &quot; </li></ul><ul><li>Height: 26&quot; </li></ul>H= 17 7/8 &quot; H= 34&quot; <ul><li>Operating Load: 2, 804 lb. </li></ul><ul><li>Installed Load: 3,505 </li></ul><ul><li>Total Travel: 8 7/8 &quot; </li></ul>
    7. 7. Case #1 – Design Custom Supports for Special Requirements Custom Designed Supports in the Field
    8. 8. Case #2 – Development of Slide Plates for High Temperature Applications Problem: Debonding of slide plate material from backing plate occurs due to high temperatures (over 350˚F.) Examples of Slide Plates Not Attached
    9. 9. Case #2 – Development of Slide Plates for High Temperature Applications Resolution: Develop Marinite insulator assembly to withstand high temperatures and high loads <ul><li>100 PSI to 2,500 PSI </li></ul><ul><li>Temperature: ½&quot; Insulator +400°F to +800°F </li></ul><ul><li>Coefficient of friction: 0.08 @ minimum pressure 0.06 @ maximum pressure </li></ul>Marinite
    10. 10. Case #3 – New Expansion Joint Design for Harsh Conditions Problem: Harsh operating conditions and environment decreased the usable life span of a metallic expansion joint
    11. 11. Resolution: Design and fabricate a replacement self-cleaning slip type expansion joint Case #3 – New Expansion Joint Design for Harsh Conditions Corrosion Resistant Inner Barrel Aluminum/Bronze Bearing Sleeve
    12. 12. Case #4 – Quick-Turn Service on Metallic Expansion Joint Problem: Failure of adjacent line anchors causes the failure of the 48” expansion joint Damaged Expansion Joint in the Field
    13. 13. Case #4 – Quick-Turn Service on Metallic Expansion Joint Resolution: Fabricate replacement expansion joint with tie-rods incorporated into the design Tie Rods: Devices, usually in the form of rods or bars, attached to the expansion joint whose primary function is to continuously restrain the full pressure thrust during normal operation while permitting only lateral deflection
    14. 14. Case #5 – Site Survey Reveals Improper Installation Problem: Spring supports malfunction because of failure to remove travel stops Constant Springs with Travel Stops in Place Variable Springs with Travel Stops in Place
    15. 15. <ul><li>Instructions for removal of travel stop pin </li></ul><ul><li>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) </li></ul><ul><li>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) </li></ul><ul><li>When the pin is centered in the keyhole, travel stop pin can be removed </li></ul>Resolution: Follow installation guidelines during opportune time to correctly remove travel stops Case #5 – Site Survey Reveals Improper Installation
    16. 16. Case #6 – Adjustment Required for Proper Functionality Problem: Improperly loaded spring supports cause inconsistent pipe system performance Decrease in Load Required Balance of Load Required Increase in Load Required
    17. 17. Case #6 – Adjustment Required for Proper Functionality Resolution: Field service must be performed on the supports in order to adjust the load to proper operating position and rectify the situation Spring Supports Adjusted to Operating Load Variable Spring at Installed Position
    18. 18. Case #7 – Site Survey Confirms Need to Replace Snubbers Problem: Miscalculation of snubber settings causes leakage of hydraulic reservoir Fully Extended Cylinder Completely Retracted Cylinder
    19. 19. Resolution: Provide new snubbers, set them correctly, and reinstall them in the piping system Case #7 – Site Survey Confirms Need to Replace Snubbers Removing the Damaged Snubber Newly Installed Replacements
    20. 20. Case #8 – Refurbish Roller Bearings in the Field Problem: High lateral loads caused failure of roller bearings on upthrust constant Resolution: Reduce lateral load and refurbish roller bearing shaft assemblies during outage
    21. 21. Case #8 – Refurbish Roller Bearings in the Field Removal of Damaged Components Installation of Replacement Parts
    22. 22. Case #9 – Field Installation of Low Friction Slide Plates Resolution: Field fabricate slide plates to be installed between the pipe stanchion and the support Problem: Initial design incorporated steel to steel sliding surfaces with high coefficients of friction (.6 to .7) Fabrication of Slide Plates in the Field
    23. 23. Case #9 – Field Installation of Low Friction Slide Plates Installation of Slide Plates in the Field New Coefficient of Friction: .08 to .12
    24. 24. Case #10 – Development of Multi-Function Support Problem: Inadequate support design causes pipe shoes to fail repeatedly
    25. 25. - The line temperatures ranged from 650°F to 1100°F. - PT&P performed full EPC services and manufactured all of the supports for this project. - Finite Element Analysis was also performed. Finite Element Analysis Resolution: Develop special design incorporating steel as the primary supporting element Case #10 – Development of Multi-Function Support
    26. 26. Case #10 – Development of Multi-Function Support Restoration of insulation after installation of new shoes Steam lines after installation of PT&P’s newly designed shoes
    27. 27. Extending the Life Span of a Pipe Support Special Paint and Coatings Neoprene-coated Assemblies Bolts coated with PTFE 3-coat Paint System Duplex Coating Over Galvanized Finish
    28. 28. PT&P’s Standard Finish (Double the life span): - Hot Dipped Galvanized Hardware - Neoprene Coated Springs Extending the Life Span of a Pipe Support Rust Prevention
    29. 29. Other Suppliers Standard Finish: - Cadmium-Plated - Painted or Unfinished “ To prevent rusting and extend the life of your spring support, go with PT&P’s standard galvanized finish with neoprene coated springs.” Extending the Life Span of a Pipe Support Rust Prevention
    30. 30. Weep Holes Help Prevent Build Up of Condensation Extending the Life Span of a Pipe Support Rust Prevention
    31. 31. Constant Support Slide Plate Bonded to Load Flange of Constant Spring Support Hot Shoe Slide Plate Added to Bottom of Hot Shoe Structural Supports Slide Plates Welded to the Inside of Structural Supports Extending the Life Span of a Pipe Support Addition of Slide Plates to Reduce Friction
    32. 32. Phosphorus Bronze Phosphorus Bronze (underside) Stainless Steel Carbon Steel Base Extending the Life Span of a Pipe Support Stainless Steel-Bronze Slide Plates
    33. 33. Grease Fitting Grout Pouring Access Point Polished Stainless Steel Countersunk Attachment Bolts Extending the Life Span of a Pipe Support Stainless Steel-Bronze Slide Plates
    34. 34. Limit Stops When the assembly is overloaded, limit stops transfer the load to the housing protecting the spring Limit Rods Prevents the Bellows from Over-extending while Restraining the Full Pressure Thrust of the System Extending the Life Span of a Pipe Support Limiting Over-loading and Over-extending
    35. 35. <ul><li>Engineering and Design </li></ul><ul><ul><li>Piping, Pipe Support and Structural Design </li></ul></ul><ul><ul><li>3D Modeling Technology </li></ul></ul><ul><ul><li>Pipe Stress Analysis </li></ul></ul><ul><ul><ul><li>Caesar II </li></ul></ul></ul><ul><ul><li>Structural Analysis </li></ul></ul><ul><ul><ul><li>STAAD II </li></ul></ul></ul><ul><ul><li>Finite Element Analysis </li></ul></ul><ul><ul><ul><li>Special Stress/Thermal Problems </li></ul></ul></ul><ul><ul><ul><li>Pro/E for 3-D Part Design </li></ul></ul></ul><ul><ul><ul><li>ANSYS for Mesh Generation + Analysis + Results Analysis </li></ul></ul></ul><ul><ul><li>Field Testing </li></ul></ul>Engineering & Design – Technical Capabilities
    36. 36. <ul><li>On-site installation guidance </li></ul><ul><li>On-site inspection/maintenance of pipe supports </li></ul><ul><li>On-site snubber inspection </li></ul><ul><li>A system of stock standard Items </li></ul><ul><li>“ On-call” engineering team </li></ul><ul><li>Available 24x7 </li></ul>Value-Added Services
    37. 37. Please send any additional questions or inquiries to [email_address] Useful Links: <ul><li>Online Quote: www.pipingtech.com/quote </li></ul><ul><li>Online Catalog: www.pipingtech.com/catalog </li></ul><ul><li>Technical Webinars: www.pipingtech.com/webinar </li></ul><ul><li>Blog: www.pipesupportsblog.com </li></ul>

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