Custom Embed Plates for Gold Mine in Cajamarca, Peru
Piping Technology & Products, Inc., designed and manufactured 150 custom embed plate pieces for Latin America’s largest gold producer. This gold mine is located between 3,500 and 4,100 meters above sea level in a northwestern province of Peru. The gold district is a 10 x 4 km zone of altered rocks with a belt of Tertiary volcanic that extends through Peru. Currently, precious metal is mined in three open quarries and according to rough estimates, the investments in the development of the gold mine amounted to about 150 million US dollars.
This project involved the production of 150, 93″ x 27″ x 1″ embed plates which required the use of 80,000 pounds of steel and anchors. The custom-designed, carbon steel, embed plates provided stability for the feed openings of four mineshafts reclaim tunnels and were scheduled to be put to use immediately. Our manufacturing process for these embed plates entails the use of a Nelson® stud welding machine to weld the studs to carbon steel plates. The carbon steel plates can be shaped to meet the rectangular mineshaft dimensions, then the studs are welded in place. Concrete is then poured around the outside of the embed plate shaft and the studs anchor the plates in place after the concrete sets. These assemblies can then be hot-dipped galvanized to protect against corrosion.
So, whether gold, silver, coal, precious gemstones, rock salt, gravel, oil shale, or some other valuable minerals are being mined, stable mineshafts are an important part of the mining process. PT&P has also manufactured embed plates suitable for large-scale projects for use in the foundations of the chemical, refinery, wastewater treatment, and power plants.
Piping Technology & Products and our subsidiaries have served many different mines in the United States, Africa, Europe, and South America. PT&P has extensive experience with key piping issues on mining projects such as wastewater treatment and abrasive media (slurry). In addition to the embed plates shown here, we have also supplied these products:
Metallic, Fabric & Rubber Expansion Joints
Pre-Insulated Pipe Supports
Variable & Constant Springs
Pipe Shoes & Hold-Down Clamps
Slide Bearing Plates
In need of embed plates for an upcoming project? Request a quote today!
PT&P REF. ORIGINAL POST 03012001
What does the red, white, and blue markings mean on a constant spring support?
Red, White and Blue Marks:
All constants are shipped with at least 3 color-coded rivets (red, white and blue).
Red: operating (HOT) position
White: installation (COLD) position
Blue: over travel (MAX AVAILABLE) position
Below are sketches of one direction vertical travel:
Below is a sketch of dual direction vertical travel:
Cold Shoe Anchor Supports with 4″ Thick G10 Micarta® Insulation
PT&P Cold Shoe Anchors are designed to support pipe sizes ranging from 12″ to 72″ in diameter. In this case, the supports were custom designed for one of the largest nitrogen generation systems for LNG in the Southern Hemisphere. The project employed a modular approach to its execution which included the assembly of large, complex, and heavy Process Modules as well as simple and relatively light Yard Rack Modules.
The saddles are fabricated from A240-Gr. 304L stainless steel and the base plates are fabricated from galvanized A516 Gr. 70N carbon steel. The insulation is 4″ thick G10 Micarta® material and capable of insulating from temperatures down to -300°F. G10 shoes are welded directly to the pipe spool, inspected, and tested prior to shipping which saves field installation and inspection time. G10 supports are also pretty durable making handling, transportation, and storage trouble-free. G10 Micarta® supports have an insignificant water/moisture absorption rate, meaning there is no structural deterioration in adverse weather, especially in the wake of heavy rain and storms.
G10 Micarta® supports involve fewer steps to manufacture allowing PT&P to support just in time lead times for fast-paced dynamic projects. PT&P has designed, extensively tested, and manufactured on G10 Micarta shoes for over 15 years. G10 is a preferred choice in cryogenic applications and demanding LNG environments for the following reasons:
Impervious to water absorption–Water intrusion into the system degrades performance and leads to many problems such as ice formation.
Superior Tensile and Flexural strength
Low Capital Expenses: Reduced field welding time, material cost, travel time, and field installation cost
Construction/Installation Savings: G10 pipe shoes can be sent to the pipe fabricator and welded directly to the pipe spool allowing for no inspection and testing requirements in the field.
Easy, trouble-free handling, transportation, and storage
Longer installation life and reduced maintenance needs
Furnace Applications – Spring Supports, Expansion Joints & Furnace Seal Bags
An industrial furnace, also known as a direct heater or a direct-fired heater, is a device used to provide heat for an industrial process. Furnace designs vary as to their function, heating duty, type of fuel, and method of introducing combustion air. Heat is generated by an industrial furnace by mixing fuel with air or oxygen, or from electrical energy. The residual heat will exit the furnace as flue gas. Types of industrial furnaces include batch ovens, vacuum furnaces, and solar furnaces. Industrial furnaces are used in applications such as chemical reactions, cremation, oil refining, glasswork, metallurgy, mechanical engineering, chemicals, ceramic, and building materials. Industrial furnaces using fossil fuels are characterized by heat losses from flue gases with a temperature of 500°C and above.
PT&P supplies many products that are well-suited for furnace applications. The first category we’ll take a look at is Engineered Spring Supports. We size furnace springs the same way as we would for a conventional variable or constant spring support. Construction may include a welded design instead of bolted and custom nameplates with the test data and ID tag. Most furnace spring supports are coated with red oxide primer to avoid potential hazards when exposed to high temperatures.
PT&P 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″ to over 6′ long. The calculated spring rate is 79 lb/sq in for an operating load of 2,804 lb. and an installed load of 3,505 lb. The housings are coated with heat-resistant paint, which protects the spring coils from corrosion and high temperatures in the furnace area.
Expansion Joints are not installed inside furnaces due to the extremely high temperatures of the environment and the piping system. Expansion joints will typically be found on the duct work and in the piping coming in and out of the furnace. In the last six months, we have shipped over 40% of our expansion joint jobs in less than 2 weeks to meet customer project deliverables.
Fabric Expansion Joints that are in-service near furnaces, typically include a 3-layer belt consisting of Silicone, Fiberglass, PTFE, and Mineral Wool Insulation. The configurations are either round, rectangular or square as seen in the examples below.
Furnace Bags are used to seal high-temperature tubes that penetrate the furnace floor. The furnace bag consists of multiple layers of flexible, flame and heat resistant, impervious fabric designed to operate from start-up to high-temperature design conditions. The bag will expand and contract with the varying furnace temperatures.
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 furnace floor. A tapered steel coil is installed around the conduit inside the bag to prevent the fabric from collapsing inward during vacuum conditions. PT&P’s standard furnace seal bag is nickel reinforced, with a special coating that reduces airborne fibers and increases tensile strength.
Saddle Support Spring Isolators for an Old Steam Chest Saddle
PT&P custom designed and fabricated “saddle support spring isolators” to replace the previous springs originally designed in 1974 for supporting an old steam chest saddle at a chlor-alkali chemical plant. Chlor-alkali plants use salt and electricity to produce caustic soda and chlorine gas. Downstream, the chlorine gas – either wet or optionally dry – can be reacted in a chemical process to produce bleach, other chlorine derivatives, or chemical feed stocks finding its way into the production of glass, plastics, pulp, paper, textiles, vinyl, antiseptics, insecticides, and a water treatment agent and in some soaps and detergents. Rising demand for chlorine and caustic soda in various industries such as automotive, pharmaceuticals, paper, and chemicals are driving the chlor-alkali market. Due to improvements in the manufacture of spring coils, PT&P’s engineering team suggested improvements to the original design using a more well-suited design that exceeds the original design specifications. These saddle supports include PTFE, 25% glass-filled slide plates bonded to the top of the assembly. They are designed to support up to 32,000 lb. each with a 6,250 lb/in. spring rate. These springs do not have the traditional spring housing typically used to encase the spring coil, instead, they are fabricated utilizing carbon steel plates in conjunction with chains and internal components. See diagram below.
The spring coils are alloy steel and were custom designed per this customer’s specified wire dia, active/total coils, and solid height. The spring supports were load tested and a quality control inspection was completed that included MAG Particle Inspection. PT&P can replace existing custom variable spring supports using the original design drawings from plants built more than 50 years ago. PT&P can also reverse engineer any spring hanger by taking detailed measurements of the support in the field and sending the information back to our shop for a quick lead time during a plant turnaround or shutdown. Many of the custom spring supports that PT&P has supplied to replace original equipment have been in service for more than 40 years.
F-Type Vertical Constant Spring Supports for a 9,000 lb. Load
PT&P manufactured compact spring supports designed for loads up to 9,000 lb. Constants are used in Geothermal, Coker units, HRSG units, and other facilities where there is substantial thermal growth in the piping. Green energy (popular to offset carbon emissions) applications such as solar, wind, and hydro also utilize constants. The figure 100 type-F constant spring supports are designed to support piping from below using a sway strut because horizontal space was not available in the system. This vertical constant spring support was the first of its kind designed and manufactured by PT&P for the largest power providers in the South using a diverse fuel and energy supply of coal, nuclear, oil, gas, hydro, and some renewable energy. The base plate is bolted directly to the top of the steel or floor and the sway strut assembly is attached to the arm (cam) of the constant. With the constant bolted in position below the piping and the sway strut assembly attached via a pipe clamp above, when the pipe goes through its upward vertical movement, the constant maintains an equal and opposite force on the piping. If there is also horizontal movement (axial or lateral) in the piping, this type of constant is well suited because of the slight “arch” in the travel path of the internal cam. The constant in the first picture maintains a constant load of 7,000 lb. while the constant in the second picture maintains a load of 9,000 lb. on the pipe throughout its 4” of total travel. They are 36” high with two gussets at the base plate for added strength encountered under hydrotest loading. They are fabricated from A36 carbon steel and hot-dipped galvanized for corrosion protection. Standard load and travel testing were performed on both constants to ensure proper field operation. Piping Technology is a leader in the design, engineering, and manufacturing of pipe supports and our products have been in service for over 40 years.
Compact Spring Supports Designed for an Oil Refinery
Compact Spring Supports
Carbon Steel w/ Hot-Dipped Galvanized (HDG)
9,000 lb. Load | +/-0.125″ Vertical Movement
PT&P custom-designed 76 compact spring supports or “disc spring” supports for a major oil refinery. This type of spring supports is ideal for locating under equipment flanges to limit excessive loads on sensitive equipment. PT&P has supplied custom compact springs for over a decade as the industry leader in plants all over the world. Compact springs are used for small travel systems to prevent equipment failures, assure safe plant operations, and reduce operational costs. Such springs can support loads equal loads to conventional springs while using 50% less space. If not addressed, pipe strain can cause misalignment, thermal expansion, and pipe-lift off resulting in strain on expensive equipment. For example in a typical refinery, upwards of $15M a year is spent on pump repair alone due to pipe strain issues. Compact springs are used in systems to support Centrifugal pumps and compressors, air-cooled heat exchangers, vessels, and steam turbines while addressing regulatory codes for API, ASME, UBC, and government compliance for organizations such as OSHA, EPA, WISHA, etc.
The springs are stainless steel Belleville washers and the housing is fabricated from A-36 carbon steel with a hot-dipped galvanized finish to protect against corrosion. The assemblies are 3″ high, designed to support a 9,000 load and movement of +/-.125″ (upward). Each assembly underwent load testing before shipment. Compact springs are specifically designed to minimize excessive loads on process equipment by managing nozzle loads and the flange seal and can be installed directly under the equipment. Another benefit of compact springs is to address corrosive environments (saltwater, marine air, or chemicals) by manufacturing them with metals like stainless steel and/or using amorphous glass coatings making them impervious to corrosion.
Pre-Insulated Pipe Supports for High Temperatures at a Phenol Plant in Texas
PT&P manufactured 48″ diameter pre-insulated pipe supports for a high-temperature pipeline at a phenol plant in Texas. Phenol is an important aromatic organic compound used in several products like plastics, nylon, epoxies, detergents, mouthwash, antiseptics, and other pharmaceutical drugs. PT&P has consistently supplied products to these types of plants for many years and has done work for most of the largest phenol plants in the world. The production of phenol from petroleum-derived feedstocks can involve temperatures, where large bore piping can reach 250°F. Phenols are used in a diverse range of end markets including construction, automotive, electronics, and fibre industries. Some other plants that utilize large bore piping at high temperatures, are Biofuels, Semiconductor, and Old Sands Extraction processing plants. These hot shoes, in particular, are designed for pipe sizes up to 48″ in diameter. They include 6″ thick by 4″ width calcium silicate insulation, hot-dipped galvanized steel, and are designed for a load of 7,000 lb. Standard quality tests were performed before shipment. At Piping Technology and Products, we can supply a wide range of different types of pipe supports to meet your design specifications. This enables our clients to order from one vendor as opposed to several different vendors to manage the supply chain for project success in the most cost-effective manner while keeping deliveries on time. This order consisted of six different types of supports such as variable assemblies, constant support assemblies, sway struts, and pre-insulated pipe supports along with associated “off the shelf” hardware items. We have served the piping industry for over 45 years providing a unique array of engineering and manufacturing experience to an ever-changing industry.
230 Chromoly Pipe Shoes & Clamps for a Natural Gas-Fed Ammonia Plant
PT&P custom-designed 230 Chromoly pipe shoes & clamps for service at a natural gas-fed ammonia plant. The pipe shoes are designed for 1″ to 42″ diameter pipelines and coated with red epoxy for high temperatures (above 750°F). Each pipe shoe design utilizes custom two-bolt pipe clamps manufactured from 387 GR. 11 CL 2 material. This design is especially useful when welding to the process pipe is prohibited. These shoes clamp around the pipe instead of welding to the pipe in order to support a given load. Special bolting is required for high temperatures utilizing A 193 GR. B16 bolting material. Quality assurance inspection was conducted prior to shipment.
Hold-Down Clamps for a Waste Disposal Facility
These hold-down pipe clamp assemblies are specially fabricated and include wedges with 25% glass-filled PTFE to absorb vibration and also serve as a buffer between the steel pipe and pipe support. Vibration can occur in Power, Solar, Biofuels, and Chemical plants because of flow-induced and/or acoustic-induced vibration due to the flow of fluids or gas/steam through the piping system. Similarly, vibration can occur in pipelines near rotating equipment such as reciprocating pumps and compressors resulting in pulsations or mechanical forces that can occur in both onshore or offshore production facilities. Vibration can be strong enough to cause premature failure or cracks resulting in unplanned shutdowns. These units shown in the photograph are custom-designed for pipe sizes up to 20″ in diameter and temperatures up to 200°F and can be adjusted to accommodate a range of heights for the T.O.S to the B.O.P. They are 21″ wide x 26″ long x 23″ high and are proven to greatly reduce vibration to acceptable levels. These hold-down pipe clamps are fabricated utilizing A 36 carbon steel plate and A 307 Gr. All-threaded rods. All components were hot-dipped galvanized and a quality control inspection was performed before shipment.
Cable Tray Support Rack Fabricated for a Groundwater Remediation
PT&P provided a cable tray support rack to a groundwater treatment facility in California. Groundwater remediation is a process whereby groundwater is purified by removing pollutants and containments rendering the water useful for crop irrigation and industrial processes. Groundwater remediation techniques can include but are not limited to, oxygen gas injection, dual-phase extraction, membrane separation, carbon absorption, and chemical oxidation. Cable trays, used in this facility, were designed to suspend electrical cables, wiring, and small-bore piping throughout the facility. Cable trays are also used in biochemical plants, solar power plants, sports stadiums, green energy plants, as well as, traditional plants such as petroleum refineries, chemical and coal-fired power plants. As a general rule, cable trays protect and carry cable and wiring from point “A” to “B” inside the facility.
This section of cable tray in the photograph (blue in color) is 25’ long, 7’ wide, and 11’ tall completely assembled. It is fabricated from carbon steel and painted with a highly chemically resistant epoxy mastic designed for immersion conditions to protect against corrosion in marine or industrial conditions. PT&P can fabricate any combination of instrument stands and structural supports from floor mounts, wall mounts to secondary supports, and more. In addition, we have the capabilities to do what few other structural fabricators can do including:
– Complete Engineering designs including FEA (Ansys) and Structural Engineering (STAAD)
– Load Testing
– Incorporation of Contact Corrosion Solutions including TPI (half-round thermoplastic) and FRP
– Incorporation of Vibration Control Solutions
– Ability to fabricate with a wide variety of metals including all grades of Stainless and Nickel Super Alloys
PT&P has worked on and is working on some of the largest water remediation projects in the US where we have supplied expansion joints, variables, fire protection insulated supports, and structural pipe supports. Our ASME shop is large, local to the United States, and includes heavy-duty equipment and specially trained personnel with over 45 years of experience making this division of PT&P ideal for large-scale projects such as this structural support as we can leverage our massive manufacturing scale and expertise.
Custom-Designed Bird Screens for LNG Service Provide a Humane Deterrent
PT&P custom-designed bird screens for a 3″ diameter pipeline at an LNG facility. Bird screens (or insect screens) are used on an open-ended pipe (i.e. exhaust) where birds or insects can be trapped inside the pipe creating a blockage. Birds such as pigeons and other roosting birds often build nests inside exposed piping and their droppings can carry diseases and even pose potential contamination and health hazards. Bird droppings have even been known to cause damage to sensitive equipment such as valves and gauges not to mention creating safety hazards on ladders, steps, and catwalks. It’s best to incorporate bird screens during the design of the refinery, chemical, power, LNG, or green energy plant and install them during construction. Our bird screens are fabricated from corrosion-resistant 304 stainless steel and can withstand temperatures up to 800 degrees Fahrenheit. They are designed to be easily assembled in the field without requiring a skilled welder or special equipment. PT&P can provide bird screens for any size piping or configuration.
Constant Spring Supports Custom-Designed for a Large Crude Oil Processing Facility
Piping Technology & Products custom-designed constant spring supports for crude oil processing at one of the largest refineries in the world. Petroleum refineries change crude oil into products such as jet fuel, gasoline, polypropylene, polyethylene, propane, sulphur, carbon black feed, and diesel that can be used for transportation, heating, feedstocks for making other chemicals, generating electricity, renewable energy, and paving roads. Piping Technology and Products was awarded this project because we were the only engineering manufacturing firm vendor of constant spring manufacturers in the world that could both design, manufacture, and test these units for the unique design conditions. These constant springs will support loads ranging from 88,185 lb. to 143,300 lb. They are designed for temperatures up to 650°F, and movements of 0.39” up, 4.72” down, -2.36” up, and 0.39” down. The Type-C constants are 67” H x 21” W x 88.25” L and the Type-F constants are 85” H X 39.75” W x 86.56” L. The F-Type springs will include graphite slide plates and are designed to support the piping from below while allowing both lateral and axial movement. All constant assemblies underwent magnetic particle inspection of welds, travel, and compression tests. Additionally, a special “cramp test” was conducted on each spring coil. A “cramp test” is done by compressing the spring coil by a specified length for a specific period of time. This assures the spring’s functionally especially when a large “wire diameter” is used to manufacture the spring coil for these high loads. At Piping Technology and Products and our subsidiaries, we specialize in designing pipe supports, expansion joints, and insulated supports for unique applications involving products not readily available. Our products are used in the CDU (crude distillation units), hydrocracking units, RFCC (residual fluid catalytic cracking), naphtha hydrotreater, and hydrodesulfurization units (also known as alkylation unit), and sulphuric acid regeneration (SAR) units in refineries.
Compact Springs for a Chemical Manufacturing Plant in Agricultural
Compact spring supports (also known as disc springs) were custom-designed for a chemical plant in the agricultural industry. We design each compact spring for specific applications. Usually, they are used in “tight” spaces where the conventional variable spring is too tall to fit the allowable space between the pipeline and supporting steel structures. In general, compact springs serve the same function as a conventional variable spring, to relieve vibration and stress in the pipeline and associated equipment. The springs supplied here are designed for loads ranging from 5,038 lb. to 15,144 lb. and spring rates from 5,904 lb./in. to 44,455 lb./in. Also, these disc springs were designed for thermal movement ranging from 0.011” to 0.46”. The assemblies are fabricated from 304 stainless steel and include Bronzphite® and stainless steel slide plates to lower the coefficient of friction due to lateral movement. Since there is lateral movement, the conventional variable spring would require “internally guided load columns”, however, these units incorporate a “guiding” feature within the spring’s design. They have an installed height of 10-1/2″ – 26”. Each assembly underwent load testing and other NDE and visual inspection by our QC department before shipment. Applications such as Skid Mounted Process Equipment, Pump and Control Skids, Skid Plants, and other types of Skid Packages where space is extremely limited are ideal applications for Compact Springs.
Clamped Pipe Shoes Custom-Designed for an Offshore Vessel Project
Special clamped pipe shoes with isolators were supplied for an offshore vessel project. Offshore renewable energy companies are exploring the viability of developing an offshore charging facility for electrified vessels as well as using ammonia-powered or hydrogen-powered fuel cells to power marine vessels. As the world’s only major manufacturer of Expansion Joints and Engineered Pipe Supports, we are uniquely positioned to service a wide range of piping needs. A total of 210 pipe shoes were fabricated from carbon steel for pipe sizes ranging in size from 1″ to 24″ diameter. They are supplied with a hot-dipped galvanized finish for corrosion resistance and range in length from 8″ to 16″ with 4″ from the BOP. These pipe shoes include a dampening isolator in between the pipe and the shoe to reduce vibration and noise. A total of 1,485 supports were supplied for this order. At Piping Technology and Products, we supply products to facilities that are helping to reduce carbon emissions and reduce dependence on fossil fuels.
Sway Struts Designed for an LNG Liquefaction and Export Facility
These sway strut assemblies were designed and fabricated for a large LNG liquefaction and export plant. Sway struts are used in a wide range of applications in power plants, chemical and refineries to restrain movement in tension (or X plane) while allowing lateral movement (in the Y and Z plane). These fig. 2100F, size C sway struts are designed with 4” adjustment for loads up to 4,500 lb. The pins are fabricated from a high alloy steel for added strength and the threaded rod ends are carbon steel and hot-dipped galvanized. The sway strut body was hot-dipped galvanized after the donut and pipe were welded. The rod ends and end brackets were galvanized a second time for added corrosion resistance after the holes for the IKO bearings and pins are enlarged to fit these component parts. The C-C dimension is 30-11/16” and a quality control inspection involving thread engagement was completed prior to shipment. Piping Technology and Products is a manufacturer of all types of pipe supports to areas all over the world ranging from sports stadiums to geothermal to infrastructure applications. In fact, many of the items you will see on our website were developed for the specific requirements of a customer who could not use the standard designs available in our industry. If you do not find what you need, or if you need technical advice, please contact us.
Pipe Rollers for an Environmental Remediation Project
These pipe rollers were designed for pipelines in an environmental remediation project. These rollers can also be used in conjunction with piping on bridges, landfill gas equipment, including oil-water & moisture separators, SVE systems, candlestick flares, blower packages, drainage systems, and many other infrastructure projects. The rollers are fabricated from cast iron, with a carbon steel frame, rods, and nuts. The units are designed for 14″, 18″, and 24″ pipe sizes and 5,000 to 7,200 lb. operating load. The rollers are designed to include 1-1/2″ thick insulation, and the size is selected to include the pipe covering saddle for the insulation. Standard quality control tests were performed prior to shipment. Roller hangers are used for the suspension of pipe from a single rod where axial movement may occur because of expansion or contraction.
High-Temperature Pre-Insulated Pipe Support for a Chemical Plant
This custom-designed insulated pipe support will be used for a high-temperature pipeline at a chemical plant in Canada. This hot shoe was customized without the u-base and modified with an extended length. It will be used to prevent the movement of a 6″ diameter pipe in the axial direction. Axial stops will be welded to the clamp O.D. in the field. The plates are 11-5/8″ O.D. x 48″ in length and fabricated from A36 carbon steel. The insulation is 2″ thick high-density calcium silicate and well-suited for temperatures up to 1200°F. Q.C. inspections and dimensional tests were performed prior to shipping.
Variable Spring Hangers Designed for a Biofuels Plant
PT&P designed and fabricated B-Type variable spring support assemblies for a biofuels plant. The variables will support pipelines that are involved in the process of converting feedstock into low-carbon synthetic crude oil. Primary biofuels are bioethanol and biodiesel. PT&P specializes in manufacturing pipe supports for high temperatures (above 750°F) applications. These variable springs will support loads up to 953 lb., insulated piping up to 1625°F, and with 1.5” upwards movement. A custom-designed 4-bolt riser clamp fabricated from A36 carbon steel for a 3” diameter pipe was also supplied for this order and used at another location in the plant. The rest of the variable spring assemblies utilized custom-designed 2-bolt pipe clamps manufactured from A240 316L stainless steel plate with A 193 GR. B8M CL.1 bolting for high temperatures. Since these variable springs were located outside the firebox and not exposed to high temperatures, they were fabricated from A36 carbon steel and hot-dipped galvanized for corrosion protection. Load and travel tests, along with Q.C. inspections were performed before shipment.
Load and travel tests, along with Q.C. inspections were performed before shipment. Biofuels are expected to double their market share by 2027. Biofuels are a subset of the new emerging demand and regulatory shift to renewables being seen in the energy sector. In addition to biofuels, other renewables include energy from solar, wind, hydroelectric, ocean, geothermal, and hydrogen sources. There has been a change in strategy for many refineries accelerated by the downturn due to COVID, to convert traditional fossil fuel refineries to renewables. With expertise and over 45 years of experience, PT&P is well-positioned to serve its customers and emerging players in the renewable energy sector. Piping Technology & Product’s specialty is the design and fabrication of products like furnace springs, constants, customized clamps, and hardware in supporting high-temperature headers and radiant coils within fired heaters.
PT&P Manufactures and Installs an 85 ft. Pipe Rack and Pipe Spools
PT&P supplied “on-time delivery” of two industrial structural steel pipe racks and the accompanying pipe spools that would be attached to storage tanks measuring approximately 120 ft. in diameter and over 85 ft. tall. Pre-Engineered Pipe Racks attached to storage tanks are used in a wide range of industries from Waste Water Treatments plants, Community Water Storage Tanks, to Above Ground Storage Tanks used in Refineries, Natural Gas, and Petrochemical plants.
PT&P leveraged its breadth of manufacturing and engineering capabilities to reduce costs for its client in the deployment of this Pipe Rack. Our focus was to complete as much work as possible in our production facility, where costs are typically far lower than in the field. We made adjustments to the design to aid in-field deployment to minimize total overall costs. This project also leveraged our capabilities with structural steel, pipe spools, TPI, and insulation. We have all of these capabilities in-house, which made it easy to fabricate the complex structures in this project.
Each pipe rack had an overall dimension of 12 ft. wide and 113 ft. tall and was fabricated from carbon steel. Due to the overall length, each frame was shop fabricated in two sections in order to transport each to the job site. Additionally, each frame was provided with lifting lugs designed by PT&P to facilitate both, the transporting of each frame half-section and the subsequent vertical lift of each completed unit. Each pipe rack was fitted with 9 pipe spools ranging in diameter from 2″ to 12″ (6 were insulated pipe spools, 3 non-insulated pipe spools). The pipe material used to fabricate the pipe spools were SA-53, SA-106, and SA-333.
Six of the pipe spools were supplied pre-insulated. At the ends of each section of pipe spool, there were bare sections of pipe where PT&P Field Service would later perform “tie-in welds” in the field.
After completing shop fabrication, the pipe racks were prepared to be transported to the job site location for final assembly before installation by PT&P Field Services. This consisted of bolting the two halves of the pipe rack together and completing the “tie-in welds” at each pipe spool connection. All of the “tie-in welds” were examined and verified by X-ray analysis. After completion of all the “tie-in welds”, PT&P Insulation Department installed insulation in the field on the 6 pipe spools requiring insulation at these connection points.
Each section of pipe spool was supported from the top of the rack by a rigid rod hanger also supplied by PT&P. Rod hanger assemblies are round steel bars normally threaded used to connect other components, such as pipe support hardware, to make a pipe hanger assembly. PT&P’s field service team installed the main pipe rack with seven pipe spools each over 86 ft. long on large storage tanks. The pipe spools were positioned on the pipe rack steel using special U-bolts to “guide” the piping.
U-bolts are u-shaped rods with threaded ends, that fit around a pipe and are attached to a supporting member. These U-bolts were coated in plastic to prevent corrosion between the pipe and U-bolt material. Additionally, Thermal Plastic Isolators (TPI) was also used to prevent corrosion between the pipe rack steel and the pipe spools. TPI can be customized in height, width, length of TPI, hole sizes, hole locations, and special shapes.
Also installed on the Insulated pipe spools were FRP wear pads that rested on the thermoplastic Isolator. FRP is also known as non-metallic wear pads, which are used for corrosion protection for uninsulated piping systems to extend the life of the pipe.
After assembly by PT&P Field Service, each complete unit was lifted vertically into position and bolted to the storage tank at the “tank connection points.” This demonstrates our ability to provide rare expertise in all facets of project management including planning, engineering design, logistics, and job site management.
We have a fully diversified operation that is customizable based on your unique needs. If you just need stock supports and standard items, we can provide them very quickly. Our engineering team can help find the best support(s) for your application. Or our field service team can inspect your pipeline conditions and recommend the best solutions. Our team also regularly completes installations and conducts on-site project management. We are your one-stop-shop for pipe supports, insulated supports, expansion joints, vibration solutions, pipe stress analysis, and more.