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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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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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