Explore how Polyurethane foam is produced, from mixing polyols and isocyanates to inspecting the final product. Learn about anchor shoe testing, lateral load testing, compressive strength testing, and axial load testing.
Hello everyone, I would like to welcome you to our Webinar on Pre-Insulated Pipe Supports. The Webinar today is hosted by Piping Technology & Products. I am Jerry Godina and I will be your presenter. If you would like to join in on the audio portion of the presentation, please make sure you select speakers/headphones in the audio choice box and double check that your volume is turned up. You can also listen to us by telephone, for the United States, just dial: (1) 516-453-0014, for countries other than the US, please refer to the list of numbers in your confirmation e-mail. The access code for this presentation is 392-247-362 Also, if you have a question during the presentation, please feel free to type a question into 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.”
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.
We would like to welcome those who are just joining our presentation on pre-insulated pipe supports We have achieved various certifications here at Piping Technology & Products, as you can see here We have the ASME U-Stamp and R-Stamp for the SWECO division of our company We are part of the Expansion Joint Manufacturers’ Association through our U.S. Bellows, Inc. divison Most recently we received the ISO 9001:2000 certification for the manufacture of hot and cold supports And additionally, we are a minority business enterprise
For many years, PT&P has been a major supplier of pre-insulated pipe supports for both cryogenic and hot temperatures in a variety of applications including: Liquefied Natural Gas Plants and Pipelines Liquefied Petroleum Gas Plants Power Plants Polypropylene and Polyethylene Plants Steam Water Pipe Lines Chemical plants Nitrogen Production Plants Cogeneration Plants
Polyurethane Foam (PUF) can be tailored to meet various load requirements of varying applications Laminated Beechwood : Permali® or Insulam® is an insulating material used in applications which require high tensile and compressive strength. It has exceptional resistance to moisture and serves as a suitable insulator where the support (flare lines & dummy legs) is exposed to harsh environment elements. Permali® or Insulam® is a phenolic laminated (densified, impregnated wood) product made from carefully selected thin beechwood veneers. These wood layers are impregnated under vacuum conditions with a special synthetic resin and then densified through the application of heat and pressure. The result is a homogenous material that combines the great strength and toughness of wood fibers with the excellent stability and dielectric properties of the most advanced thermosetting. Micarta : Temperature range is Ambient to -300F, Compressive strength is 22,000 PSI, Tensile strength is 28,000 PSI Foamglas ® insulation is a lightweight, rigid insulation composed of millions of completely sealed glass cells. Advantages include low moisture. absorption, constant insulating efficiency, fire protection, corrosion resistance, long-term dimensional stability and physical strength.
These photographs show our manufacturing facility. This is an overview of the foam department where we manufacture various types of insulation for our pre-insulated pipe supports. These particular photos were taken at a time that we supplying supports to two or three large LNG plants Additionally, we have over 100,000 lb. of insulation materials in stock so that we can quickly manufacture pre-insulated supports and ship them to our customers
Here are some photos in our cold shoe assembly area. At the bottom-left, you can see a number of cold shoes lined up and waiting for inspection prior to being shipped (point to top photo and bottom-right photo) In the background of these photos showing our cold shoe assembly line, you can see the shelves with our stock pre-insulated support materials that we were just talking about on the previous slide
Here is our pre-insulated support shipping area We provide special crating for insulated support materials The crating material and packaging material is specially designed to eliminate damages that could occur due to the environment Here you can see various ways that our pre-insulated supports have been prepped for shipping
As we mentioned previously, we have several hundred thousand pounds of stock inventory on hand of pre-insulated support components However, as you can see in this photo, we also keep a stock inventory of our standard pre-insulated support items which are completely fabricated and ready to be welded to a piping system in the field
This diagram shows the workflow of how our pre-insulated supports are manufactured First thing we do is pour the polyurethane into the molds in order to create the insulation for the supports Meanwhile the steel is being cut and welded together for the remainder of the support After the polyurethane is set, we remove the molds and machine it and fit it to the required pipe size using a template To complete this process, we combine the steel and the insulation in our assembly area to create the pre-insulated support We will be going more into depth on this process in the following slides.
Once again, if you have any questions, I want to remind you that we do have experts standing by to answer your questions. Again, we would like to show you our polyurethane foam process with a few more illustrations The picture on the left here, shows our mixing machine that we use to produce the polyurethane foam The arrow in the photograph is the machine’s mixing “head” – how it works is that two chemical components are actually mixed within the machine, an “a” and a “b” component that come together in the mixing head and the foam then comes through the hose shown and into the mold The machine to the right is another one of our mixing machines Here at PT&P we try to separate the orders at each particular machine so that we can produce different densities of foam and keep a continuous flow of equally dense pipe supports being manufactured at each machine, eliminating the need to frequently shut down the machine in order to change the foam density
Here is an example of one of our steel molds that we have mentioned before We have a variety of molds available for different pipe sizes Once the polyurethane flows into the mold from the mixing machine, we place the lid over the foam in order for it to set. The foam will then rise to fill the entire mold. It is kind of like baking a cake, as the foam will rise to fill all of the voids within the shape of the form. Additionally, we fabricate all of our own molds that are necessary for the polyurethane process
I’d like to welcome all of those who have just joined in. Today’s presentation is on pre-insulated pipe supports. This photo shows two people getting ready to pour the foam into the mold, and you can see the steel mold (like the one shown on the previous slide) pictured here next to the mixing machine We actually have an overhead crane the picks up the mold and places it in the exact location where the hose of the machine comes down so that the mold can be filled with the foam (point at the hose coming down to meet the mold)
As mentioned before, the polyurethane rises due to a chemical reaction going on inside of the mold, and it heats up Cure time refers to the amount of time that it takes the polyurethane to rise and to fill the voids within the mold and set and is actually a function of insulation thickness and density Prior to the foam being poured we apply a thin layer of wax within the mold to allow for easy demolding of the polyurethane foam during this process
This photos again shows the demolding process when the foam is completely set and removed from the steel mold
Next, we visually inspect the foam to make sure that there are no voids or inconsistencies in the foam We also check the outside diameter of the foam to make sure that the desired insulation thickness has been achieved The pipe template shown in the bottom photo is used to ensure a snug fit between the insulation and the pipe in the field
The next step involves machining the foam to fit a specific pipe size or insulation thickness (point at the top photo) This particular machine actually cuts the foam to the desired length as well This bottom photo shows a great deal of inventory. When we are expecting to fabricate a particularly large number of supports, we will fabricate the foam and have it readily available for assembly when the steel components are completed
Here we show another additional feature, that we offer at PT&P, called monular mastic This process involves applying an additional material to the foam (point to the white lines) to ward off moisture
We make pipe shoes of different densities, shapes, and sizes according to each particular customer’s needs and requirements. The following are some of our cryogenic pipe shoe designs… This top photo shows dual density insulation – A lot of times in a piping system, the upper layer of insulation is not generally supporting the load, so the upper layer can be comprised of a lower density insulation. In this particular photo ( point to individual layers) , the top layer of polyurethane foam is manufactured in a 10 lb density and the lower layer is manufactured in a 14 lb density. The lower layer is supporting the load, thus it has a bit higher density. We also manufacture shoes with staggered layers (point to lower photo) . This design prevents both an axial and lateral direct air path on the pipe in the field. This system of layered insulation prevents condensation, frost, and ice buildup on the cryogenic pipeline. Here at Piping Technology & Products, we have received photographs from our customers that show large chunks of ice build-up that has formed on the pipe, so this design would actually prevent that from happening.
These photos show our assembly area Depending on the design of the shoe, the steel may actually be bonded to the polyurethane as shown in the top photos The bottom photo shows another optional feature of cryogenic shoes called a vapor barrier. There are different types of these barriers available such as aluminum, stainless steel, and carbon steel
Here are some other examples of other large diameter cryogenic pipe shoes The photo on the left shows a cryogenic shoe designed for a 30” pipe and has 7 1/2” of insulation. The photo to the right shows a cold shoe designed for a 40” pipe and has 8 ½” of insulation Note again the staggered layers (point to them in the photo) that we mentioned earlier that prevent the direct air path to the pipe.
These photos show some larger shoes with that same basic design These particular shoes are 24” in diameter with 2” of polyurethane foam insulation Once again, the shield is visible which prevents moisture from getting inside the shoe Additionally (point to shoes in top photo), you can see a little flap on top of the bolts which prevents moisture from getting in where the two pieces of steel meet
Here we are showing you some additional examples of cryogenic pipe shoes. Notice again the staggered layers on both of the photos Additionally, you can see in the photo (point to the shield) a shield which is an added feature that surrounds the two halves of insulation to help prevent moisture from getting inside the shoe
This photo shows a range of pre-insulated cryogenic supports. As you can see, some of the supports have the staggered layers while others do not These supports can be fabricated for just about any pipe size according to each customer’s needs from a very small diameter to a larger diameter (point to the different diameters in the photo)
Here is an example of a 48” inch diameter cryogenic support that we fabricated for a LNG plant Comparing this photo to the previous photo gives you an idea of the range of diameters that we are able to produce here at PT&P This particular support has 8” of insulation, and as you can see, it also has the staggered layers that we’ve seen in the other photos
This photo shows a custom designed 36” diameter cryogenic pipe shoe that has base stops incorporated into the design to prevent lateral and axial movement of the anchor on the pipe. The steel anchors will eventually be welded to the pipe in the field in order to prevent movement. This particular design is able to support 63,000 lb. of axial load, and temperatures as low as -300 ºF
This an example of a drawing that we supplied to a local customer It’s an anchor design for an insulated support that they required
This project was done for a customer on the upper East coast Interesting thing about this project is that this client actually sent us part of the process line (point to the pipes in the various supports) You can see the pipe coming out of the support We built a mold around the pipe and then injected the mold with polyurethane foam Therefore the final product is shoe that perfectly fits the pipe in the process line As you can notice, there is no bolting involved in the process
This photo shows 16” base insulated supports that were used for a flare line application Note here (point to the upper portion of the shoe) that the upper portion is manufactured entirely from stainless steel In most flare line applications, it is not necessary to insulate the actual pipe line, so the shoe is designed to be bolted directly to the pipe to serve as an anchor and the bottom portion includes a base plate that is welded directly to the existing steel The insulation (point to the insulation pieces) is permali. This material is derived from a very early form of the insulated support which was simply a wood piece that people used to stick under the pipe to serve as an insulator between the process pipe and the existing steel. Our engineers, using this same concept, have designed a laminated wood block to serve as insulation and it has a great deal of resistance from the environment such as water and high temperatures
This is a list of some of the experience that we have with cryogenic supports, most of the jobs being for LNG plants or ethelyne plants (point out some of the customers) So as you can see, we have a wide range of experience Many times these customers will have their own particular insulated support design We are able to fabricate both our own standard catalog designs, and those of our customers, providing quite a bit of flexibility in our fabrication capabilities
This is an example of a very large diameter shoe that we fabricated for a high temperature pipe We refer to these supports as “hot shoes” This hot shoe was designed for an 84” pipe, most likely a steam line. The insulation material (point to it on the photo) is called calcium silicate, which is the same material that is used underneath the space shuttles Calcium silicate insulation is good for temperatures up to about 1,000 degrees Fahrenheit
These photos show additional examples of custom supports for high temperature pipelines (point to photo on the left) Sometimes we will add a high density calcium silicate insert inside the shoe Some of the high temperature materials are Marinite or Firetemp We are able to add structural inserts for high loads The steel that is surrounding the insulation is generally painted since galvanizing is not a particularly good choice for high temperature lines, because galvanized materials can sometimes melt in high-temperature situations Again, if you have any questions, feel free to ask our panel of experts that we have standing by
These photos show a compressive strength test on polyurethane foam Using an additional testing machine that we built (point to it in the photo on the right), we are applying a load to the 14 lb density material below the steel to see how it performs
Here at Piping Technology & Products, Inc, we also perform product testing These photos show an apparatus that we designed to test the various insulation materials such as Micarta, polyurethane, permali block, etc. We apply various loads and here we are running nitrogen through the pipe to test how it performs with the cold temperatures
Here are some photos of the same test This bottom photo shows our Quality Control manager taking a reading of the temperatures on the outside of the insulation This gives us an idea of the delta, and the quality of the insulation performance of this particular support
One of our clients designed their own support and wanted us to test the performance of the support Here we are doing a pull test on a 30” diameter base insulated support We applied liquid nitrogen and a vertical load to the support and tested its force This was to help the client evaluate the design to see if it would be feasible for them
* These photos show us testing the axial load of the support while it is at cryogenic temperature
Here at Piping Technology & Products, we offer a variety of value added services We have a field service team that can dispatch within a day’s time to assist our customers in the field They are able to provide installation guidance and can inspect your piping systems for problems or just general maintenance
We offer a 24 hour quick-turn service if you have emergencies that arise All you need to do is log on to our website at www.pipingtech.com, click on emergency, fill out the short form, and we guarantee a response time within 30 minutes to respond to your request This will actually contact various members of our staff on their cell phones so that they can immediately provide feedback to our customers’ needs
In conclusion, we just want to remind you that these pre-insulated supports that we discussed serve in a variety of applications including power plants, LNG plants, and nitrogen production plants We keep over 100,000 lb of raw material in stock to quickly manufacture pre-insulated supports for our customers And finally, that we have a field service team that is ready within a day’s notice to inspect the supports in your piping systems to perform repairs or provide replacements and can also help to install new supports in the field Thank you very much for attending today’s webinar presentation on pre-insulated pipe supports. If you still have any questions, please send those in right now as our panel of experts is standing by for a quick question and answer session for the entire group.
Pre-Insulated Pipe Supports for Both Cryogenic and High Temperature Applications
Pre-insulated Pipe Supports Webinar December 9, 2010 PIPING TECHNOLOGY& PRODUCTS, INC. Presents… Your Presenter is: Jerry Godina Lead Pipe Support Designer
<ul><li>Pipe Shields, INC. </li></ul><ul><li>Insulated Pipe Support </li></ul><ul><li>Commercial & Light Industrial </li></ul><ul><li>Heavy Industrial – based on Mounted, Anchors </li></ul><ul><li>Pipe Riser Clamps </li></ul><ul><li>Fronek A/D E. </li></ul><ul><li>Hydraulic Snubbers </li></ul><ul><ul><li>Short strut </li></ul></ul><ul><ul><li>Adjustable strut </li></ul></ul><ul><li>Mechanical Snubbers </li></ul><ul><li>dynA/Damp Compensating Strut </li></ul><ul><li>ASME Nuclear Qualified </li></ul><ul><li>SWECO FAB, INC. </li></ul><ul><li>Pressure Vessels </li></ul><ul><li>Pig Launchers/Receivers </li></ul><ul><li>Spectacle/Line Blinds </li></ul><ul><li>Instrument Supports </li></ul><ul><li>ASME/Misc. Fabrication </li></ul><ul><li>ASME U-Stamp R-Stamp </li></ul><ul><li>U.S. Bellows, INC. </li></ul><ul><li>Metallic Expansion Joints </li></ul><ul><li>Thin-wall, Thick-wall </li></ul><ul><li>Rectangular Expansion Joints </li></ul><ul><li>Fabric Expansion Joints </li></ul><ul><li>Slip-type </li></ul><ul><li>Member of EJMA </li></ul>Who is PT&P <ul><li>PIPING TECHNOLOGY & PRODUCTS, INC. </li></ul><ul><li>Engineered Pipe Supports </li></ul><ul><ul><li>Variable, Constants, Big-tons </li></ul></ul><ul><ul><li>Vibration Control Devices – Snubbers, Sway Struts </li></ul></ul><ul><ul><li>Support Assembly Components – Clamps, misc. </li></ul></ul><ul><ul><li>hardware </li></ul></ul><ul><ul><li>Pre-insulated Pipe Supports – Cryogenic/cold & Hot </li></ul></ul><ul><ul><li>Applications </li></ul></ul><ul><ul><li>Fabricated Pipe Shoes, Guides & Anchors </li></ul></ul><ul><li>Slide Bearing Plates </li></ul><ul><li>Anchor Bolts, Embed Plates </li></ul><ul><li>Member of MSS, SPED, APFA </li></ul>
Certifications <ul><li>ASME U-Stamp </li></ul><ul><li>EJMA </li></ul>ASME “R” Stamp Certified <ul><li>ASME NS Certified </li></ul><ul><li>ISO 9001:2008 Certified </li></ul><ul><li>Minority Business Enterprise (MBE) by the City of Houston </li></ul>
Overview <ul><li>Liquefied Natural Gas (LNG) Plants </li></ul><ul><li>Liquefied Natural Gas (LNG) Pipelines </li></ul><ul><li>Liquefied Petroleum Gas </li></ul><ul><li>Polypropylene Plants </li></ul><ul><li>Polyethylene Plants </li></ul>For many years, Piping Technology & Products, Inc. has been a major international supplier of pre-insulated pipe supports for a variety of applications: <ul><li>Chilled Water Pipelines </li></ul><ul><li>Steam Water Pipelines </li></ul><ul><li>Chemical Plants </li></ul><ul><li>Nitrogen Production Plants </li></ul><ul><li>Cogeneration Plants </li></ul><ul><li>Power Plants </li></ul>
Experience Piping Technology & Products, Inc. has extensive experience with several types of insulation materials, some are shown here: Permali ® Micarta Foamglas ® Marinite ® Polyurethane Firetemp ® Calcium Silicate
Manufacturing Facility - Foam Shop <ul><li>> 100,000 lb. raw materials in stock </li></ul>
Manufacturing Facility - Cold Shoe Assembly Line <ul><li>insulated supports assembly area </li></ul>
Manufacturing Facility - Stock Inventory Stock inventory for standard items
Insulated Supports Design PT&P’s insulated supports act as load bearing members while simultaneously minimizing energy dissipation. Our supports can be designed for vertical, axial and/or lateral loading combinations in both low and high temperature applications. Higher Density PUF Lower Density PUF Multiple Layers
Insulated Pipe Shoe Design When designing insulated pipe shoes, PT&P’s standard procedure is based on an analysis of… 1. Load Requirements 2. Temperature Details Design Load Resisting Load Energy Dissipation
Guides and Anchors The axial and/or lateral load capabilities are dependent upon the strength and rigidity properties of the insulation. Guide Anchor
Current Projects We are currently fabricating insulated supports utilizing cryogel in our manufacturing facility. Insulated Support During Fabrication Complete Insulated Support Cryogel PUF Carbon Steel Base
Production - Workflow Pour Insulation (H.D. PUF) Finish Foam (machine foam, fit to pipe size template, apply vapor barrier, etc.) Fabricate Steel (pipe shield, pipe shoe, etc.) Assemble/Bond Pipe Shoe (combine insulation and steel)
Production - Polyurethane foam <ul><li>Automatic Foam Mixing Machine </li></ul><ul><ul><li>uses shear mixing head </li></ul></ul><ul><ul><li>produces homogeneous mixture of polyol and isocyanate to form polyurethane </li></ul></ul>Mixing Head (shear mixing, mixes polyols and isocyanates)
Production - Polyurethane foam Steel Molds for foam production
Production - Polyurethane foam <ul><li>Foam is poured into molds </li></ul><ul><ul><li>steel molds are fabricated in PT&P shop </li></ul></ul><ul><ul><li>great flexibility to meet volume production demands </li></ul></ul>Steel mold (for given ID and OD)
Production - Polyurethane foam <ul><li>Demolding of PUF </li></ul><ul><ul><li>Cure Time function of insulation thickness and insulation density </li></ul></ul><ul><ul><li>Wax allows for easy demolding of PUF </li></ul></ul>
Production - Polyurethane foam Demolding of PUF
Production - Polyurethane foam Pipe Template (ensures snug fit between insulation and pipe) Visual Inspection : Check resulting foam for inconsistencies.
Production - Polyurethane foam Machining Foam (automatic routing machine, band saw machine) Cut to length foam
Cryogenic Pipe Shoes Polyurethane foam after secondary work.
Cryogenic Pipe Shoes Dual Density Shoe (more economical and effective from insulation standpoint) Staggered Layers (eliminates vapor path, both axially and laterally) 30 lb. 10 lb. 14 lb. 20 lb.
Cryogenic Pipe Shoes Steel and Foam Bonded (PUF is bonded to steel) Vapor Barrier (aluminum)
Cryogenic Pipe Shoes - Large Diameter Three-Layer Cold Shoes 30 " Pipe with 7 ½" Insulation 40 " Pipe with 8 ½" Insulation
Cryogenic Pipe Shoes 24 " pipe with 2 " of insulation
Cryogenic Pipe Shoes 8 " pipe with 6 " of multi-layered insulation
Cryogenic Pipe Shoes various sizes of polyurethane insulated supports
Cryogenic Pipe Shoes - Large Diameter ColdShoes 48 " pipe with 8 " of insulation for LNG plant
Cryogenic Pipe Shoes 36 " cryogenic pipe shoes that include base stops to prevent lateral and axial movement of the anchor
Cryogenic Pipe Shoes - LNG Line Anchor Modules
Product Testing - Lateral Load Test Pull test for 30 " dia. base insulated support QC Mgr. simulates operation condition by applying liquid nitrogen & vertical load to the support PT&P & client engineers reviewing the results
Product Testing - Axial Load Test at Cryogenic Temperature Axial Load Test at Cryogenic Temperature
Value-added Services On-site Field Services <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 Web-based Emergency Services PT&P’s “On-call” engineering team guarantees a response time of 30 minutes
Conclusion <ul><li>Pre-Insulated Supports serve in a variety of applications including LNG pipelines, power plants, nitrogen production plants, and chilled water pipelines </li></ul><ul><li>PT&P has over 100,000 lb. of raw material in stock </li></ul><ul><li>Our field service team is available to inspect current pipe supports for repair/replacement or determine where they need to be installed in your piping system </li></ul>
<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>Please send any additional questions or inquiries to: [email_address] Pre-Insulated Pipe Supports Webinar Thank You for Attending….