Pipe Supports and Expansion Joints for Furnace Applications


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  • Hello everyone, I would like to welcome you to our Webinar on Variable Spring Supports. 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 or if you prefer, you can ask questions after the presentation during our “Questions and Answers Session.” http://webs.purduecal.edu/civs/research/mechanical-engineering-department/hydrogen-reformer/ convert natural gas into hydrogen through a series of catalytic reactions. The combustion process in the furnace provides the heat to maintain the chemical reaction inside the catalyst tubes. 
  • 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.
  • 9500 lb. Load C-Type Constants Modified to fit in Constricted Areas Near a Furnace
  • Pipe Hangers are designed to control: Longitudinal weight stress in the piping system without creating additional stresses Piping system loads on equipment without limiting or reducing static loads Hanger loads on building structure And physical clearances of hanger components with piping and structure Let’s look at the basic steps in the hanger design: Step 1 is to determine the location of all the hangers Then calculate the hanger loads due to the piping weight Next calculate the thermal movement of the piping at each hangers location Step 4 is to select the hanger type and finally check all clearances
  • Difference -  The major differences between standard springs and furnace springs are in their construction and their intended use. Furnace springs operate in much the same way as other variable spring supports. They are designed to support the pipe or tubes that are subjected to vertical thermal movement. The design changes are necessary because furnace springs are exposed to extreme temperatures. Coatings -  Furnace springs are almost always coated with red oxide primer in order to avoid any potential hazards when exposed to high temperatures. Standard springs are usually hot dipped galvanized, which, when exposed to high temperatures, tends to melt the zinc coating. The molten zinc can then cause damage to the surrounding pipe and equipment. Construction -  Whereas many of the standard variable spring components are interchangeable, the furnace spring assemblies are constructed from components unique to its application and intended use. The furnace spring incorporates a welded design for the housing assembly unlike standard spring housings that use a bolted configuration. The internal components of the furnace spring are designed to center the spring coils within the spring’s housing to prevent misalignment. In addition, the spring housing is modified to accommodate lug attachments on existing furnace tubing and equipment. Special fabricated casings, spring coils, and nameplates may also be used to accommodate increased travel. Design -  Some furnace springs are designed in order for the spring to be used as a means to determine the loading of the catalyst tubes. In these applications, an exact spring rate is determined for each assembly. The exact spring rate (which may differ slightly from published spring rate values) can then be used to determine the weight of the tubing system in order to balance the unit.
  • Location of blog post: http://www.pipingtech.com/blog/2004/01/09/furnace-spring-assemblies-up-to-13000-lbs-for-a-chemical-refinery/ Pictures of them crated in shipping: W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\oct\\boxed_support_102103 KBR JOB… Jan. 2004 Job# 71755 (pic of rods) W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\oct\\rods_71755R1 Piping Technology and Products, Inc. designed and manufactured furnace spring assemblies for a chemical refinery in Saudi Arabia.  Each pipe hanger assembly consists of a variable spring, rod, clevis, hex nuts, and pipe attachments. Unlike other variable springs which are designed to have bolted housings, these furnace springs are designed for spring coils with a customer specified spring rate installed in a welded housing. The sizes of these Fig. PTP-2 and Fig. PTP-4 ranged from 90-170, with a total travel of 1 1/4″ to 5″, and loads varying from 850 lbs to 13,300 lbs. Prior to the final welding, trial fit-up and cycle test were performed to ensure unrestrained movement throughout the designed travel range. The spring assemblies were then calibrated to determine the exact spring rate prior to shipping. 1,520 Spring Assemblies for a Chemical Plant PT&P recently manufactured 1,520 PTP-2 and PTP-4 spring hanger assemblies designed specifically for a furnace application. These custom variable springs have welded components as opposed to bolted components found in standard assemblies. Due to the space limitation within the furnace, the spring coils were set in a welded housing which allows for the springs to be closely oriented within a smaller spatial envelope. The pipe hanger assemblies are made from carbon steel, consisting of variable spring, rod, and riser clamp components. Instead of galvanizing, the assemblies were coated with a red-oxide primer due to the high temperature operating conditions of the furnace. This prevents the possibility of molten zinc (from the galvanizing process) contaminating the furnace tubes. The springs are designed for loads of 143 to 660 lbs. and for total travel ranging from 3/4 to 2″. Each assembly was pre-assembled to ensure free movement throughout the spring’s travel range before welding the bottom closure plate. Prior to shipment, all assemblies were calibrated to determine the exact spring rate and then were set to the customer’s designated cold load position. These springs are then located and installed into the furnace based on the spring rate.
  • Engineered Spring Hanger for Reformer Furnace in Venezuela Engineered spring hangers shown are being calibrated and tested at Piping Technology & Products, Inc., Houston, Texas Facility. A digital load cell is attached to the hydraulic press that guarantees calibration to the exact loads specified. The spring hanger will support the tubes in a reformer furnace destined for Venezuela. August 1993
  • Piping Erection for Hydrogen Re-Boiler http:// www.dormanengg.com/project.php?&page =6
  • Radiation Coils Gas Vent Heater http://www.vdlkti.be/?page/3315322/Coils+and+Piping+Systems.aspx http://www.tragsqatar.com/gallery/gallery.htm
  • Location of pics: W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\may\\j.r_constants Location of blog post: http://www.pipingtech.com/blog/2003/09/26/950-lb-load-c-type-constants/ Sept. 2003 Job #70610 (Nooter Eriksen)… found that job number on galvanized constants in the same folder FABRICATION 9500 lb. Load C-Type Constants PT&P recently designed and manufactured sixteen PTP-200 C-type constants modified to fit in constricted areas near a furnace of a chemical facility.  These constants are designed to travel from 5 1/2” to 19” and are specified to carry loads ranging from 245 to 924 lbs. They were fabricated from A36 plates with 4140 pins. Due to the proximity of the pipes and other equipment, the front part of the constant frame was cut to allow the pipe to move freely. Load and travel testing was performed to ensure quality and precise performance.
  • http://www.pipingtech.com/blog/2006/01/04/88-constant-supports-for-a-hydrogen-reformer-plant/ These Figure PTP100-A size 40 and 51 constant supports, made of A36 carbon steel, are used to support pipeline systems. Each is 24″ long, 10 1/2″ wide, and 51 1/2″ high. These constants are capable of supporting loads ranging from 1,165 lb. to 2,260 lb. with a travel range of 13″ to 14 1/2″. PT&P specifically designed and fabricated each constant for specific dimensions provided by the customer. Standard load and travel testing was completed for quality assurance. 81599 82411 Location of pics: Location of blog post: http://www.pipingtech.com/blog/2002/05/03/c-type-constants/ C-Type Constants May. 2002 Job #____ Piping Technology & Products, Inc. designed and manufactured 70 horizontal, C-type constants for a furnace application located in Venezuela. The sizes of the Figure 200 constants ranged from 32 to 64, with a total travel of 4.5 to 10.5, and loads varying from 1,149 to 5,149 pounds. The constants are provided with a custom designed PT&P Figure 270, which consists of a double lug horizontal traveler versus a single lug. Within the horizontal travel, the constants are designed to handle 8 of horizontal movement and support a rod that remains vertical throughout pipe movement. Constants for a Radiant-tube Support System The photograph above shows a large number of specially designed constant spring supports being prepared for shipment to Chile. These constants are the key component of a reforming furnace, radiant tube support system designed for one of the world’s major engineering and construction firms. Piping Technology’s engineers designed these units to fit in the limited space available inside the furnace and provided optional bolting patterns so attachment to the supporting structure could be made even if the radiant tube support system assumed a competitor’s design. Jan . 8, 1994
  • W:\\digital_camera\\2005\\job82411_constants
  • Location of pics: W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\may\\furnace_springs Location of blog post: http://www.pipingtech.com/blog/2002/02/15/400-lightweight-vertical-constant-load-hangers/ Feb. 2002 Job #70454 MAYBE (Nooter Eriksen) for Formosa Plastics Plant (Point Comfort, Texas)… found that job number on galvanized constants in the same folder 400 Lightweight, Vertical Constant Load Hangers Piping Technology & Products, Inc. specially designed and fabricated four hundred 100-C, vertical constant load hangers for a plastics plant in Texas. The constants will be used to support a furnace standing three levels high. In the plant, thirteen single beams confined to limited space will each hang thirty constants, therefore PT&P engineers were required to design the constants to weigh less than 150 pounds. The 136-pound constants with travels of 10 inches upward and a supporting load of 950 pounds, are 33 7/8″ in height and 8 7/8″ in width. They are also supplied with shop prime, painted finish to safeguard against the extremely hot temperatures of the furnace area. In order to insure quality and proper operations of the constants, a prototype was built and tested to MSS standards.
  • Variable Springs to Meet Travels Needed to Support Furnace Tubes of a Hydrogen Reformer Piping Technology & Products, Inc.  specially designed and fabricated hundreds of altered Type A variable spring hangers in order to accommodate the special travel and spring rate needed to support the furnace tubes of a hydrogen reformer in Venezuela. In order to accommodate customer specified travel and spring rate, modified spring coils were required. With a travel of 8 7/8, the variable spring hanger casing lengths were increased from the standard size of 32 inches to over 6 feet long. The calculated spring rate is 79 lb/sq in for an operating load of 2,804 lbs. and installed load of 3,505 lbs. The housings are coated with a heat resistant paint, which protects the spring coils from corrosion and high temperatures of the furnace area.
  • To adjust a spring hanger after inspection, set to the desired position by turning the turnbuckles and load column. When the nameplate is present indicating the design hot load, adjustments can be made during operation, but a cold load adjustment needs to be made during a shutdown.
  • In the case you want to use your existing spring support, re-calibration is an option as long as the support is a constant spring support, in good operating condition, has an operating load range greater than fifteen thousand (15,000) pounds and the cost of field time and equipment is less than the cost of a new spring hanger.
  • A few thoughts during shutdown: Are the lines and equipment temporarily supported while repairs are being made? To prevent having to readjust the spring, I need to re-install the travel stops. If the name plate is missing, stencil the proper installed and operating positions or provide loads for re-calibration.
  • 87 Fabric Expansion Joints for a Furnace Application at a Chemical Plant in Texas U.S. Bellows, Inc. manufactured 87, rectangular fabric expansion joints for a furnace application at a chemical plant in Texas. The joints were designed at 11″ W.C. and 750 degrees F for ½ ” axial and lateral movements. The fabric belts on these joints are composed of three layers. They were equipped with a telescoping liner and 2″ thick insulation pillows to reduce the heat transfer. http://www.usbellows.com/blog/2002/08/30/87-fabric-expansion-joints-for-a-furnace-application-at-a-chemical-plant-in-texas/
  • Our engineering and design department is involved in the following processes: -Piping, Pipe Support and Structural Design -3D Modeling Technology -Pipe Stress Analysis, in which we use Caesar II -For Structural Analysis, we use STAAD II -Our engineering and design department uses Finite Element Analysis for many projects: -FEA is used for Special Stress and/or Thermal Problems -It is used in 3D Part Design -They use ANSYS for Mesh Generation and Analysis and Results Analysis -Our Engineering and Design department is also involved in Field Testing.
  • PT&P offers on-site installation guidance, inspection and/or maintenance of pipe supports and snubber inspection. We carry a system of stock standard items and have an “on-call” engineering team available 24x7.
  • Since we don’t have much time this evening, you may want to check out our website; there you will find a plethora of technical information, including different Tests we carry out, FEA Analysis, and much more.
  • That concludes our Webinar on Pipe Supports and Expansion Joints for Furnace Applications …. I hope everyone enjoyed the presentation and as a reminder, we have a staff of experts standing by to answer any questions you may have. You can just chat them now while in session until the end of the hour or you can also send them to us by e-mail at info@pipingtech.com
  • Pipe Supports and Expansion Joints for Furnace Applications

    1. 1. Piping Technology & Products, Inc.and wholly owned subsidiaries: US Bellows Sweco Fab Pipe Shields Anchor/ Darling Ent. PresentsFurnace Support Products
    2. 2. Presenter Jerry Godi na Spring Suppo rt Designer Lead
    3. 3. PT&P and Subsidiaries 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 U.S. Bellows, Inc. SWECO Fab, Inc. Pipe Shields, Inc. Fronek A/D Ent., Inc. Metallic Expansion Joints  Pressure Vessels Insulated Pipe Supports  Hydraulic Snubbers Thin-Wall and Thick-Wall  Pig Launchers/Receivers  Commercial & Light Industrial - Short & Adjustable Strut Rectangular Expansion Joints  Spectacle/Line Blinds  Heavy Industrial – Base  Mechanical Snubbers Fabric Expansion Joints  Instrument Supports Mounted Types, Anchors  dynA/Damp Compensating Slip-Type Expansion Joints  ASME/Misc. Fabrication  Pipe Riser Clamps Strut Member of EJMA ASME U-Stamp & R-Stamp ISO 9001-2008 Certified ASME Nuclear Certified
    4. 4. Furnace Application Supports Spring Supports Expansion JointsVariables Flanged Assembly Furnace Bag Constants
    5. 5. Basic Steps in Design Check clearances Furnace Spring Select hanger type Calculate thermal movement of piping at Calculate each hanger hanger loads due locationDetermine to pipinghanger weightlocations 1 2 3 4 5
    6. 6. Furnace Springs vs. Standard Springs Variables FURNACE STANDARD SPRINGS SPRINGS CONSTRUCTION - Welded design for - Bolted assembly housing assembly - Interchangeable - Centers the spring sub-components coils within the housing - Standard name and accommodates lug plate with catalog attachments data - Custom name plate with test data and identification tag COATINGS Red oxide primer in Hot dipped order to avoid potential galvanized. When hazards when exposed molten zinc Constants to high temperatures. coating melts, it can damage surrounding pipe and equipment. APPLICATION Used as a method for Designed to load calibration accommodate load at support location
    7. 7. Variable Furnace Spring Supports FABRICATION • Minimum amount of components • Close tolerances among moving components • Seamless pipe (A106 carbon steel) • Painted (usually with red oxide primer, some are painted white) • Not galvanized (galvanize would melt and drop below creating more weight) • Coil is coated with neoprene • Coil guides (permanent and moving)
    8. 8. Variable Furnace Spring Supports FABRICATION AND ASSEMBLY • Coil being compressed into can to establish lower working range load • Closure plate being positioned for final welding
    9. 9. Variable Furnace Spring Supports CONFIGURATIONS A-Type Variable Springs B-Type Variable Springs • 1,520 Furnace spring assemblies for a • 251 Furnace spring assemblies chemical plant for fertilizer production in a chemical plant • Total travel range from 3/4” to 2” • Load range: 1,042 lb. to 15,512 lb. • Load range from 143 lb. to 660 lb. D-Type Variable Spring Assemblies • Furnace springs for a chemical refinery • Total travel range from 1-1/4” to 5” • Load range from 850 lb. to 13,300 lb.
    10. 10. Variable Furnace Spring Supports Working Range TESTING Minimum • Tested over the entire working range • Exact spring rate determined • Primarily set at the “calibrated” load position Working Range Maximum Calibration Load
    11. 11. Variable Furnace Spring Supports APPLICATION • Hydrogen Re-Boiler • Manifold Piping Support Locations • C-Type Variable Springs
    12. 12. Variable Furnace Spring Supports APPLICATION • Radiant Coils in Gas Vent Heater • Variables will be used in place of counter-weights
    13. 13. Constant Furnace Spring Supports FABRICATION • Minimum amount of components • Close tolerances among moving components • Painted (usually with red oxide primer, some are painted white) • Not galvanized (galvanize would melt and drop below creating more weight) • Coil is coated with neoprene
    14. 14. Constant Furnace Spring Supports CONFIGURATIONSA-Type Constants for a Hydrogen Reformer C-Type Constants • Load Capacity Range: • Load Range: 1165 lb. to 2260 lb. 1149 lb. to 5149 lb. • Travel Range: • Travel Range: 13” to 14-1/2” 4.5” to 10.5” • Dimensions: • Includes a Double 24” long Lung Horizontal 10-½” wide Traveler 51-½” high • Horizontal Travel: 8” • Fabricated from Carbon Steel D-Type Constants for a Radiant Tube Support System in a Furnace • Custom designed to fit in a limited amount of space inside the furnace and provided with optional bolting patterns for attachment to the supporting structure
    15. 15. Constant Furnace Spring Supports TESTING • Tested over the entire working range • Primarily set at the installed position • Set to the load required by the customer • Create a test report to ensure the correct load and total travel required
    16. 16. Constant Furnace Spring Supports APPLICATION • Support furnace standing 3 levels high • 13 single beams confined to limited space will each hang 30 constants
    17. 17. Furnace Spring SupportsINSTALLATION Procedure for Installing Variable Furnace Springs • Securely attach spring housing to the existing structural or foundation member • Attach hanger rod where applicable • Attach all related assembly hardware
    18. 18. Furnace Spring Supports INSTALLATION• Perform any hydro-testing as applicable• Remove travel stops Critical Elevation Established via• Adjust the load indicator Built-in Adjustability of Variable Spring Assemblies to calibration load setting
    19. 19. Furnace Spring Supports INSPECTION NOTE: Furnace must be shut-down for visual inspectionTen Point Operational Integrity Check:  Beam attachment  Beam attachment pin  Spring hanger attachment  Load flange movement  Spring coil corrosion  Check load indication for hot load  Note load deviations  Turnbuckle/locknuts  Threaded rod/weldless eye, hex nuts  Pipe clamp attachment pin
    20. 20. Adjustments / MaintenanceAdjustments: Maintenance: • Due to inadequate support of a piping• Spring hangers can be set to desired system, static loads can cause position by turning the turnbuckles/load problems, such as: column – Leaking flanges• When nameplates are present indicating – Continued pump & turbine problems design hot load, adjustments can be related to bearings, seals and made during operation misalignment.• When nameplates are present indicating – Sagging lines and liquid trapped in low design cold load, adjustments can be sections made during shutdown (assuming the – Increased system stresses resulting in supported load has not changed) potential piping failures.
    21. 21. Re-calibration / Replacement Criteria Re-calibration: – Spring hanger missing a name plate – Operating load range > 15,000 lb. – Spring is in good operating condition – Cost of field time & equipment required is less than the cost of new spring hanger Replacement: – Sign of damage and/or broken components – Excessive corrosion – Equipment to be supported has been modified/changed from its original design
    22. 22. Shutdown/Isolation Procedures – Lines/equipment must have a temporary support while repairs are made – Re-install travel stops when the line is taken out of operation (shutdown) to prevent line/equipment movement and possible readjustment of the springs – If re-calibration is recommended and name plate is missing, the variable spring should be stenciled at the proper installed and operating positions or provide these loads – Remove spring hanger assembly
    23. 23. Future Webinars on Standard SpringsWe also host more in-depth Webinars on standard springs! Keep a look-out in our newsletters for the invitation to… Variable Springs Constant Springs
    24. 24. Furnace Expansion Joints General Characteristics – Flexible junction between the floor of the furnace and the pipe penetration openings – Used to prevent heat loss – Used to compensate for high temperature gradients between duct work / piping leading in and out of furnaces – Constructed primarily of non-metallic bellows
    25. 25. High Temp. Furnace Bags FABRICATION • Bag consists of multiple layers of flexible, flame and heat resistant, impervious fabric • Designed to operate from start up to high temperature design conditions and expand and contract with the varying furnace temperatures • Our bags are nickel reinforced with a special coating that reduces airborne fibers and increases tensile strength
    26. 26. High Temp. Furnace Bags APPLICATION • Openings between the floor of the furnace and the pipe penetration openings can cause heat energy loss. • A penetration bag type seal can prevent the energy loss during expansion and contraction. • The furnace bag permits movements while providing an airtight closure to prevent heat loss.
    27. 27. High Temp. Furnace Bags APPLICATION • Stainless steel clamps or band straps connect one end of the pipe that goes through the penetration opening and the other to another sleeve in the floor. • A tapered steel coil is installed around the conduit inside the bag to prevent the fabric from collapsing inward during vacuum conditions.
    28. 28. High Temp. Furnace Bags INSPECTION / REPLACEMENT • Look for rips or tears in the fabric and openings at the seal • Observe any damage or corrosion of the clamping elements • Seal can function through maintenance “shut-down” cycles • Easy to replace after several years of operation
    29. 29. Flanged Expansion Joints FABRICATION • Fabric belt consists of maximum of 3 layers • Layers can be fabricated from: Silicone, Fiberglass, PTFE and Mineral Wool Insulation Reinforced AluminizedSilicone Fabric Glass Cloth Multi-layered Fabric BeltPTFE Coated Silica Oxide Glass Cloth Glass Cloth
    30. 30. Flanged Expansion Joints CONFIGURATIONSRound Rectangular or Square
    31. 31. Flanged Expansion Joints APPLICATION • Flanged Expansion Joints expansion joints are usually used on the duct work and piping leading in and out of furnaces
    32. 32. Flanged Expansion Joints INSPECTION• Check for signs of leakage or loss of pressure• Inspect any distortion or yielding of anchors, hardware, bellows, and piping components• Observe for any unanticipated movement of piping due to pressure• Check guides and other movable parts for evidence of binding REFURBISHMENT / REPLACEMENT• The unit can be refurbished by replacing the fabric belt and using the same metal flanges after many years of service
    33. 33. Value-Added ServicesProject Stock Inventory Capabilities At Piping Technology & Products, we can: – Pre-build a large quantity of assembly components – Stock full quantity of project for different deliveries
    34. 34. Value-Added ServicesEngineering & Design Department Engineering and Design Piping, pipe support and structural design 3D modeling technology Pipe Stress Analysis • ANSYS Finite Element Analysis • Special stress/thermal problems • Pro/E for 3-D Part Design • ANSYS for Mesh Generation + Analysis + Results Analysis – Field Testing
    35. 35. Value-Added ServicesField Services & 24x7 Emergency Service On-site installation guidance On-site inspection/maintenance of pipe supports On-site snubber inspection A system of stock standard Items “On-call” engineering team Available 24x7PT&P’s “On-call” engineering team guarantees a response time of 30 minutes
    36. 36. Value-Added ServicesTechnical Literature Online “Over 450 Project Examples” www.pipingtech.comPressure Balanced FEA: Plate Thickness Expansion Joints and Pipe Stress Fatigue Testing Inspection and Maintenance of Supports
    37. 37. Thank You for Attending… PT&P Webinar: Pipe Supports and Expansion Joints for Furnace Applications Request a PDH Certificate at enews@pipingtech.comPlease send any additional questions or inquiries toinfo@pipingtech.comUseful Links: • Online Quote: www.pipingtech.com/quote • Online Catalog: www.pipingtech.com/catalog • Technical Webinars: www.pipingtech.com/webinar • Blog: www.pipesupportsblog.com