ASME Defines Inspection Criteria for High Energy Piping

B31.1 Operations and Maintenance

According to ASME B31.1 Chapter VII Par. 140 a program shall be established for the assessment and documentation of the condition of all CPS (Covered Piping Systems) in power plants.

CPS Systems are defined in Chapter 1 Par 100.2, as systems on which condition assessments are to be conducted. This includes the following systems as a minimum.

NPS 4 and larger main steam, hot reheat steam, cold reheat steam, and boiler feedwater piping.

NPS 4 and larger systems that operate above 750°E (400°C or above 1,025 psi (7,100 kPa)

 

Other systems may be included as CPS by an Operating Company, based on their judgment. Appendix V of the code is titled ‘Recommended Practice for Operation, Maintenance, and Modification of Power Piping Systems’. This addendum is non-mandatory; however many  Power Industry operating companies’ insurance carriers are now invoking Appendix V with increasing frequency, and this is affecting the conditions of their agreements with the operating companies.

Piping Technology and Products Inc. (PT&P) has for some time been performing surveys and assessments in accordance with part H of Par. 140, which requires hot and cold walk-down readings and assessment of pipe supports, operated within the creep regime of the pipe.  These assessments are helpful in identifying, sagging lines, deformation of supports, and damage caused by upset conditions, and/or incidents, attributable to operational malfunctions, dynamic/thermal or hydraulic events.

PT&P has been performing this service for many power generation companies. Preparation of documentation, retrieval, and compilation of files for a CPS assessment, has just been completed for a major U.S power generation company. Ten large power plants were involved, and the original predominantly high-energy pipe support drawings, all engineered and designed by PT&P, were retrieved from PT&P archives dating back ten years.

We will be happy to answer any of your technical questions about our survey capabilities, as well as any other engineering or field services that your organization may need.

If you need assistance, we are available 24×7 for emergencies or reach our field service team directly.

 

High-Temperature Pre-Insulated Pipe Supports Designed for 42″ Dia. Pipelines

High-Temperature Pre-Insulated Pipe Supports Designed for 42" Dia. Pipelines

Pre-Insulated pipe supports were designed for high-temperature service at an oil refinery for a client that specializes in the engineering and design of fired heaters, furnaces, pre-heaters, and heat recovery systems. These high-temperature pipe supports were fabricated from carbon steel and designed for pipe sizes ranging in 36” – 42” diameter and are not only used for new construction but also upgrades and revamps. The “hot shoes” were designed with the addition of “Spring Washers” (not shown here) to maintain consistent clamping force when the pipe expands and contracts. The insulation is 3″ thick and comprised of High-density Calcium Silicate (asbestos-free) structural inserts treated with water repellant. Standard quality tests were performed before shipment. Our hot shoes are used extensively in Refineries, Styrene Plants, Hydrogen Plants, LNG Facilities, Semiconductor Fabrication Facilities, and General Building Construction.

Compact Spring Supports Custom-Designed for Large Diameter Piping at a Chemical Plant

Compact Spring Supports Custom-Designed for Large Diameter Piping at a Chemical Plant

These compact spring supports were custom-designed to support large diameter piping at a chemical plant that manufactures ethylene, propylene, butadiene, benzene, propylene oxide, styrene monomer, and other derivatives and gasoline-blending products. They are designed for large loads (13,623 lb. to 24,038 lb.) and a small confined space with limited thermal movement (from 0.2″ to 0.3″). Compact spring supports (or disc springs) minimize excessive loads on sensitive equipment, so these types of spring support the same load as a conventional variable spring but with a smaller “working range” and utilizing 25-50% less space. They are ideal for locating under equipment flanges or other locations where space is limited. The housing is fabricated from A-36 carbon steel and hot-dipped galvanized to protect against corrosion. They have an installed height of 13″ – 15″ and are 21″ in diameter. The “disc springs” are engineered using stainless steel. Each assembly underwent load testing and other NDE prior to shipment.

Constant Spring Supports for Heat Recovery Steam Generators (HRSG)

Custom Constant Spring Supports for Heat Recovery Steam Generators

PT&P custom-designed constant spring support assemblies for heat recovery steam generator at a combined-cycle power plant. These power plants utilize gas turbines, steam turbines, heat exchangers along with other components to make use of “exhaust waste” for a more efficient system. These 200-F Type constants were fabricated from A36 carbon steel and include a hot-dipped galvanized finish. The spring coils are formed from alloy steel and are neoprene coated. They are designed for an operating load for up to 886 lb., and up to 6″ of maximum travel. They are placed beneath the unit being supported and allow for movement in the vertical direction (up or down). The dimensions are 13″ W x 31″ L x 18-1/2″ H. Standard load and travel tests along with a quality control inspection were conducted prior to shipment.

Compact Spring Supports Designed for a Heat Exchanger at a Large Oil Refinery

Compact Spring Supports Designed for a Heat Exchanger at a Large Oil Refinery

These compact spring supports were custom-designed to support a heat exchanger at an oil refinery. They were designed to support loads up to 12,000 lb. and a movement of 0.039”, with space limitations of 3″ in height. These compact springs are fabricated from carbon steel and utilize engineered Belleville (disc spring) washers. 25% glass-filled (PTFE) slide plates are bonded to the top of the load flange and provide a low coefficient of friction.

Constant Spring Supports for a Leading Energy Transportation and Midstream Service Provider

Constant Spring Supports Custom-Designed for a Leading Energy Transportation and Midstream Service Provider

PT&P custom-designed constant spring support assemblies for an energy facility in Canada. These 100–E Type (layout B) constants were supplied with an extended hanger rod and fabricated from A36 carbon steel with 5160 alloy steel coil springs. They are designed for an operating load from 2,370 lb. to 9,240 lb., and movements from 1-1/2” to 8-1/4”. The dimensions are 12” W x12” L x 30” H and 14” W x 19” L x 53” H. Load and travel tests along with a quality control inspection were conducted prior to shipment.

Custom High-Temperature Insulated Pipe Supports with Rollers for a Vaporizer

Custom High-Temperature Insulated Pipe Supports with Rollers for a Vaporizer

Pipe Shields, Inc., a division of PT&P custom-designed insulated pipe supports with rollers for high-temperature pipelines for a Vaporizer located in Malaysia. The “hot shoes” are fabricated from A36 carbon steel and include FireTemp 28 PCF & 18 PCF. The supports are 79” OD x 18” long x 87” high and designed with Hilman rollers for supporting the pipe from below while allowing it to move axially with minimum friction. Quality control inspections were performed before shipping.

U-Type Constant Spring Supports with Stainless Steel Slide Plates

 U-Type Constant Spring Supports with Stainless Steel Slide Plates

PT&P custom-designed U-type constant spring supports for an oil refinery in Texas. Constants can be utilized in refineries within blocks such as hydrogenation units, naphtha desulfurization units, and fluid catalytic crackers. The spring’s frame is manufactured from A36 carbon steel and hot-dipped galvanized to protect against corrosion. For instances where there was axial and lateral movement, 240 Gr. 304 slide plates were installed on the load flanges of the constants. The constants supplied are designed for an operating load ranging from 1,085 lb. up to 17,480 lb. and horizontal travel from 2.5” to 6”. The overall dimensions range in size from 17” H x 20” W x 31” L to 28” H x 26” W x 66” L. Load and travel tests per industry standards were performed prior to shipment.

Hold-Down Pipe Clamps for a Steam Methane Reformer (SMR) Supplying High-purity Hydrogen

Hold-Down Pipe Clamps Designed to Limit Vibration Caused by Rotating Equipment and Avoid Damage to the Surrounding Piping System

PT&P has extensive experience involving the custom design and fabrication of hold-down pipe clamps for piping systems and skid mounted units for the power, chemical, and refineries industries throughout the world. These hold-downs are custom designed to limit vibration caused by rotating equipment and avoid damage to the surrounding piping system. They are fabricated from carbon steel with a hot-dipped galvanized coating and include PTFE slide plates to reduce the friction between the pipe and clamp, combined with fabric pads to reduce vibration dampening. The hold-downs are designed for pipelines ranging in 2” to 16” diameter. They range from 3″ wide x 9-1/8″ long to 8″ wide x 25-3/4″ long, and designed for an operating temperature of 200°F. We performed a Q.C. visual inspection prior to shipment. PT&P can custom design and fabricate hold-downs for any pipe size application. In addition to hold-downs, PT&P also offers other types of vibration control devices to accommodate different pipe orientations and locations.

Over 1/2 a Million Instrument Stands for LNG Service and Operator

Over 1/2 a Million Instrument Stands for LNG Service and Operator

PT&P provided and designed instrument pipe stands in a multi-billion dollar high production liquefied national gas facility. In addition to LNG facilities, these floor mounted fabricated welded instrument stands are also used in a variety of applications including chemical plants and refineries. The units measure 40” wide by 54” high and are fabricated from A36 carbon steel with a hot-dipped galvanized finish fabricated locally in the United States. They are custom-designed with a vertical supporting section divided to yield two supporting sections. Their gusseted base design allows for the units to be either bolted to the foundation using anchor bolts or welded onto structural pipe rack steel. These primary modules can be used independently or together with secondary modules (such as cable mounts, elbow mounts, or u-bolt mounts) in order to display instrument indicators in any position.

Constant Assemblies Custom-Designed for Hot Service at a Leading Plastic Manufacturing Plant in North Carolina

Constant Assemblies Custom-Designed for Hot Service at a Leading Plastic Manufacturing Plant in North Carolina

Type: Custom-Designed Constant Spring Supports
Size: PTP-100 B-Type | 16” x 24” x 30”
Material: A36 Carbon Steel | Hot-dipped Galvanized| Epoxy Coating
Design: Load Range: 2,280 lb. to 7,143 lb. | 2″ Total Travel
Testing: Q.C. Inspection | Load and Travel Tests

PT&P custom-designed constant spring supports with assembly rods for a manufacturing company. The constants were fabricated from A36 carbon steel, hot-dipped galvanized, and painted with an epoxy coating. The assemblies are designed for an operating load ranging from 2,280 lb. to 7,143 lb. with 2” of total travel. Standard load and travel test and Q.C. inspection were completed prior to shipment to North Carolina.

PT&P Designed and Fabricated Variable Springs for a Refinery in Texas City

PT&P Designed and Fabricated Hanger and Base-Type Variable Springs, Constant Spring Supports, and Sway Struts for a Refinery in Texas City

Type: F-Type Variable Spring Support Assemblies
Design: Operating Loads from 3000 lb. to 4000 lb.
Movement of 1”
Material: Carbon Steel
Testing: Load & Travel Test |  Q.C. Inspection

Pictured here is a Type G variable spring hanger assembly designed for an operating load up to 4000 lb. and 1” movement. This type of support assembly is formed by welding two standard spring assemblies to the ends of a pair of channels. The Type G assembly is especially adaptable for avoiding interference in spaces where the headroom is limited. The assemblies are fabricated from carbon steel and underwent spring load tests before shipment.

Constant Spring Supports Designed for LNG Service in Louisiana

Constant Spring Supports Designed for LNG Service in Louisiana

Type: B-Type Constant Spring Supports
Size: 11-5/8 W x 41” L x 19” H to 21” W x 88” L x 38” H
Material: A36 Carbon Steel | Hot-dipped Galvanized
Design: Operating Load Range: 3,170 lb. to 48,400 lb.
Movement of 3” to 8”
Testing: Q.C. Inspection | Load and Travel Tests

PT&P manufactured B-type constant spring supports for LNG service in Louisiana. These constants are fabricated from A36 carbon steel with alloy steel 5160 spring coils. The constants are designed for an operating load range of 3,170 lb. to 48,400 lb., and movements from 3” to 8”. They range in size from 11-5/8 W x 41” L x 19” H to 21” W x 88” L x 38” H. To avoid delivery delay, a standard frame was paired with an oversized coil and coil housing. The lugs were rotated 90 degrees from the standard to allow the hanger to swing beyond +/- 4” of side-to-side swing. Standard load and travel tests were performed prior to shipment.

6-1/2 Foot Diameter Custom Insulated Sliding Pipe Shoes for HVAC Service at a Semiconductor Manufacturing Facility

6-1/2 Foot Diameter Custom Insulated Sliding Pipe Shoes for HVAC Service in Oregon

Type: Insulated Sliding Pipe Shoes
Size: 78″ NPS | 12″ L x 90″ H x 85″ D
Material: HDG Carbon Steel | High-Density Calcium Silicate
Design: +/- 3″ Axial & +/- 1″ Lateral Movements
Operating Loads up to 88,000 lb.
200°F Temperature Pipeline
Testing: Q.C. Inspection | Visual & “Fit-Up” Tests

PT&P custom designed insulated sliding pipe shoes for HVAC service at a semiconductor manufacturing facility. The shoes are fabricated from A36 carbon steel and hot-dipped galvanized for corrosion resistance, and include insulating material consisting of high-density calcium silicate. The insulated sliding shoes are designed for a 78″ pipe size with overall dimensions of 12” L x 90” H x 85” D to accommodate +/- 3″ axial and +/- 1 lateral movement at a pipeline temperature of 200°F. This design can accommodate operating loads of 88,000 lb. with each shoe weighing approximately 1,200 lb. Our quality control department performed visual and “fit-up” tests for this “Rush” shipment. *image shows product during assembly

Insulated Pipe Supports for a High Temperature Pipeline by Pipe Shields, Inc.

Insulated Pipe Supports for a High Temp. Pipeline by Pipe Shields, Inc.

Type: Pre-Insulated Pipe Supports “Hot Shoes”
Size: 1″ to 3″ NPS | 1″ to 2″ Thick Insulation
Material: HDG Carbon Steel | Calcium Silicate
Design: Operating Temp.up to 1200°F
Operating Loads up to 1000 lb.
Movements of +/- 4-1/2″
Testing: Standard Q.C. Inspections

Pipe Shields, Inc., a division of PT&P custom designed insulated pipe supports for high-temperatures in a chemical plant. The “hot shoes” are fabricated from A36 carbon steel and include a hot-dipped galvanized finish. They range in nominal pipe size from 1” to 3” and include 1”-2” thick calcium silicate insulation. The supports are designed for an operating temperature up to 1200°F and operating loads up to 1000 lb, with +/- 4 -1/2 movement. Quality control inspections were performed before shipping to Indiana.

F-Type Variable Spring Supports Designed for a Petrochemical Plant in Canada

F-Type Variable Spring Supports Designed for a Petrochemical Plant in Canada

Type: F-Type Variable Spring Support Assemblies
Size: Heights up to 12-3/4”
Spring Casing Diameters from 6-5/8” to 8-5/8”
Base plates from 9″x 9″ to 13-1/4” x 13-1/4″
Design: Operating Temp.: -49°F to 122°F
Operating Loads from 697 lb. to 6093 lb.
Movements of 0.04″ to 0.2”
Material: Hot-dipped Galvanized Carbon Steel
Testing: Load & Travel Test |  Q.C. Inspection

Piping Technology and Products, Inc. recently designed and manufactured F-Type variable spring supports with internal load columns for a petrochemical plant in Canada. The variables are fabricated from carbon steel that is able to accommodate low temperatures (A516-GR. 70N). The operating temperature ranges from -49°F to 122°F while supporting operating loads from 697 lb. to 6093 lb. and movements of 0.04″ to 0.2”. They are designed to accommodate installed heights up to 12-3/4”, with spring casing diameters from 6-5/8” to 8-5/8”, along with base plates from 9″x 9″ to 13-1/4” x 13-1/4″ for installing either by bolting or welding in the field. Load and travel tests, along with visual Q.C. inspections were performed before shipment.

B Type & C Type Constants for an Oil Refinery in Louisiana

B Type & C Type Constants for an Oil Refinery in Louisiana

Type: B-Type & C-Type Constant Spring Supports
Size: 12″ x 18″ x 20″ to 12″ x 12″ x 32″
Material: A36 Carbon Steel | Hot-dipped Galvanized
Design: Operating Load Range: 475 lb. to 1,250 lb.
Movement of 2-1/4″ to 5″
Testing: Q.C. Inspection | Load and Travel Tests

PT&P fabricated multiple B-Type and C-Type constant spring supports for an oil refinery in Louisiana. The constants are fabricated from A36 carbon steel and hot-dipped galvanized. The dimensions range from 12” x 18” x 20” to 12” x 12” x 32”. The operating load range is 475 lb. to 1,250 lb. with movement of 2-1/4” to 5”. Standard load testing was completed to ensure quality and performance.

Custom Technical Training Sessions – P.E. Credits

Boost Your Pipe Stress Engineering Expertise with PT&P Customized Virtual Training

While sometimes overlooked in the broad scope of equipment and engineering in an operating plant, Pipe Stress Engineering and knowledge of Expansion Joints and Spring Supports continues to be a sought after skill in industries dealing with high-temperature processes including Semiconductor, Oil and Gas, Chemical, and Power. PT&P’s customized virtual training options are offered free of charge and allow you and your team to develop these skills by having an understanding of the fundamentals of Pipe Stress Engineering and how the components used to manage Pipe Stress are designed, inspected, and maintained.

Piping Technology & Products would like to make sure we stay connected with key customers during this challenging time and find ways to continue supporting your business. While promoting social distancing measures to protect our employees and communities, we are offering online Zoom technical training sessions designed to benefit Engineers, Maintenance Planning, Reliability, Turnaround Planning, Vibration Inspection, and Operators/Technicians. The sessions count as PDH credit, and we offer training on a variety of topics, including the following:

Basics of Pipe Stress — Thermal expansion and methods of managing stress from thermal expansion

Spring Supports — Design of Spring Supports, Hot and Cold Settings, Appropriate use of travel stops

Dynamic Restraints — Applications of Sway Braces/Struts and design of Hydraulic and Mechanical Snubbers

Static Restraints — Types of Materials used for pre-insulated supports for insulation

Friction Solutions — Material selection for Slide Plates

Vibration Solutions — Solutions to reduce vibrations and noise, lowering maintenance costs

Contact Corrosion Solutions — Cost-effective corrosion management solutions

Expansion Joints — Overview of managing pressure thrust and squirming, types of movements, and movements supported by different types of expansion joints including Single, Universal, Hinged, Gimbal, Slip, and Fabric. Also includes an overview of the parts of the expansion joint and their purpose.

Please let us know what topic or combination of topics would be most useful to you and your team, and we would be happy to customize a training session for you. Would you be interested in participating? When would be a good time to set up a session?

We hope that you will find some value in this training opportunity and the other online resources we offer on our website (pipingtech.com), such as our webinars (pipingtech.com/webinars & usbellows.com/webinars). We are also available to provide assistance on any specific technical questions you might have if you would like to discuss ongoing projects or current issues you are facing.

Please let us know how we can be of assistance, and we hope you stay safe and have a wonderful day.

F-Type Constant Spring Supports Designed and Manufactured for Gas Plant

F-Type Constant Spring Supports Designed and Manufactured for Gas Plant

Type: F-Type Constant Spring Supports
Size: 36″- 87″ Length | 24″ Height
Material: A36 Carbon Steel | HDG | SS Slide Plates
Design: 13,500 lb. Load | 250°F | 17.5″ Travel
Testing: Q.C. Inspection | Load and Travel Tests

PT&P custom-designed multiple horizontal F-Type constant spring supports for a gas plant in Saudi, Arabia. The constants are provided with stainless steel slide plates and custom-designed for 17.5” total travel. They are fabricated from carbon steel, hot-dipped galvanized and painted to withstand a highly corrosive environment. The assemblies are 24” in height, 36” – 87” in length, designed for an operating temperature of 250°F and loads up to 13,500 lb. Load tests and dye penetrant testing was conducted prior to shipment.

B-Type Variable Spring Hangers for an LNG Facility in Texas

B-Type Variable Spring Hangers for an LNG Facility in Texas

Type: B-Type Variable Spring Support Assemblies
Size: 100-B-Type & 200-B-Type | 13″ to 120″ Pipe Elevation
Design: Operating Loads: 9,320 lb. to 28,2000 lb.
Spring Rates 4,700 lb./in. & 5,320 lb./in
Material: | Hot-dipped Galvanized Carbon Steel
Testing: Load & Travel Test |  Q.C. Inspection

PT&P designed B-type variable spring hanger assemblies for an LNG facility in Texas. They are supplied to support piping ranging in elevation of 13” to 120” and are designed for operating loads from 9,320 lb. to 28,2000 lb. The spring rates range from 4,700 lb./in. for the Short Spring up to 5,320 lb./in. for the Standard Spring. They are furnished with a clevis and one lug that will be welded to the supported pipe or trunnion and are fabricated from carbon steel with a hot-dipped galvanized finish. Standard load and travel tests were completed prior to shipment.

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