PT&P custom-designed big ton spring supports with stainless steel rollers for a chemical plant in Brazil. The frame is fabricated from carbon steel and the shim plates are 2205 duplex stainless steel. The design specified that these big tons are placed in a large “oil pan” that was fabricated from AR400 steel. AR400 steel is abrasion resistant and has a minimum hardness of 360 on the Brinell scale and a nominal hardness of 400. The stainless steel rollers are designed to fit inside the “oil pan” and the big tons are placed on top of the rollers. Oil is then placed inside the pan providing continuous lubrication for the assembly while accommodating the axial or lateral movement of the structure. These big ton spring assemblies include special coils and neoprene drip shields to protect the coils and oil in the pan from debris. The big tons are 26-1/2″ x 33″ x 26-1/2″ with a movement of 0.499″ down and a spring rate of 13,450 lb./in. They are designed for an operating load up to 78,318 lb. and underwent load testing prior to shipment. PT&P, along with our team of engineers and designers, specializes in making the impossible, possible. Over the years, there are many instances where our clients have come to us with unique and unusual applications requiring a product not yet developed or requiring the modification of an existing product.
PT&P custom-designed and fabricated variable spring supports for a furnace application at a chemical plant in California. The furnace cans are manufactured from carbon steel and painted with red oxide primer because they are exposed to high temperatures where hot-dipped galvanizing is not feasible. The springs are designed for an operating load of 1,261 lb., with movement of 9″ and dimensions of 6″ x 52″ in length. Load tests were performed prior to a 12-14 week shipment.
Within a Reformer, heat-resistant cast alloy tubes are used to produce hydrogen during the process of desulfurization in refining plants, ammonia, methanol, and fertilizer plants. These catalyst tubes (also called reformer tubes) are periodically changed within the units after years of operating under high pressure and temperatures. The new or replacement tubes are manufactured from alloy material that can be lighter or heavier than the previous tubes installed. As a result of this weight change, new furnace springs may also need to be replaced.
Most recently we completed a project for a key client for the largest refinery in Central America with a specialized design using our nano-constant, the world’s smallest constant spring hanger. It supports 765 pounds of load and 7″ of travel in a 0.89 cubic foot envelope (7″ x 10″ x 22″). This particular furnace application required very stringent requirements of load deviation of less than 3% and all supports were made from stainless steel to meet furnace requirements. So, for these particular units, no coating was required since they were manufactured from stainless steel. In order to accomplish this special requirement, our engineering team designed and manufactured a new constant load test machine in-house.
We have manufactured various types of furnace springs and constants for a variety of EPC firms over the past few decades. Our experience and knowledge of the different designs and configurations have helped us to become one of the leading manufacturers of springs and pipe supports for furnace applications.
PT&P REF. ORIGINAL POST 07232018
These constant spring supports for an ethane cracker for one of our largest and oldest customers who we worked with almost daily for years. As a matter of fact, a majority of the hangers in this plant are supplied by PT&P dating back to 1971. Today, the new cracker project was designed to take advantage of cheap shale-derived ethane feedstock.
The constant supports were supplied with horizontal travelers with a special “brush strip” help limit the entry of foreign objects. The constants are designed to support an 8” diameter pipeline leading into a furnace. Each spring coil is neoprene coated and the spring can housing is hot-dipped galvanized to protect against corrosion. This type of rigid spring hanger uses a coil or series of coils to accommodate pipe movement throughout the piping system. These particular constant assemblies are designed for horizontal movements ranging from 1” to 6.6” and loads up to 1320 lb. We can customize any material, finish, dimension, load, load adjustment, travel, and travel stops, as well as provide sensors for remote monitoring.
This project was unique in design and testing requirements requested by the client and their customer. Every constant support we build is load-tested by our quality and production teams. In some cases, the customer will ask to witness the testing of a single unit which we do on a regular basis. However, for this project, every constant spring was witness tested with the client’s inspection and engineering teams located at our manufacturing facility utilizing our custom in-house designed test machine.
These clamps were installed in a coal-fired power plant on the Ohio River and this plant features one of the largest smokestacks in the world at 1038 feet. For this plant, sub-bituminous coal is used in conjunction with steam turbine technology to generate thermal power with over 10k Gigawatts of output annually.
Heavy-duty pipe clamps are bolted around the pipe and connect to the remainder of the pipe hanger assembly. This assembly included a Fig. 30 Forged Turnbuckle, which is also available on Amazon as a stocked item. PT&P maintains an extensive inventory of pipe clamps required for pipe hangers and support assemblies. These Fig. 80 Three-Bolt Pipe Clamps are fabricated from carbon steel and for this project, the pipe clamps were painted with a red oxide primer. These pipe clamps are designed for 36” diameter pipelines and are recommended for suspension of cold pipelines or hotlines where little or no insulation is required and are capable of supporting both horizontal and vertical piping. A visual inspection test along with “sample pipe” dimensional checks were conducted prior to shipment.
Such clamps can be used in any type of piping system for various industries such as chemical, biofuel, food processing, and refining plants. We have the ability to get such products at your jobsite overnight given our pipe hanger hardware inventory of over 1 million pounds, our quick order system through Amazon, and 24/7 manufacturing and engineering support provided by our teams around the clock.
Do you need this exact pipe support? Skip the line and order our Standard Pipe Support Components on Amazon. From forged carbon steel turnbuckles and light or heavy 2-bolt, 3-bolt pipe clamps, riser clamps to long tangent u-bolts, we stock standard sizes for your quick-turn orders.
Need a standard product quickly? Or know what you need and don’t need a quote? Skip the line and order through Amazon. From forged carbon steel turnbuckles and light or heavy 2-bolt, 3-bolt pipe clamps, riser clamps to long tangent u-bolts, we stock standard sizes for your quick-turn orders.
Fig. 30 Forged Carbon Steel Turnbuckle
Fig. 60 Heavy Two-Bolt Pipe Clamp
Fig. 70 Light Three-Bolt Pipe Clamp
Fig. 80 Heavy Three-Bolt Pipe Clamp
Fig. 90 Riser Clamp
Fig. 100 Long Tangent U-Bolt
PT&P manufactured Fig. 550B Sway Braces for preventing excessive loading on 12″ diameter flanged expansion joints leading into a containment shelter. The sway braces include our Fig. 30 Forged Turnbuckles, spring casing. and size 3 spring coils along with other internal components. They are fabricated from carbon steel, hot-dipped galvanized, and designed for a spring rate of 450 lb./in. These sway braces measure 91-3/8″ pin-to-pin and are suitable for full deflection forces from 200 to 1,800 lb. Initial pre-compressed spring forces are from 50 lb. to 450 lb. to dampen vibrations, oppose pipe sway and absorb shock forces.
Sway braces are recommended for controlling vibration, absorbing shock loadings; guiding or restraining the movement of the pipe resulting from thermal expansion; bracing a pipeline against sway. The vibration control and sway brace is shipped and ready for installation. The rod coupling rotates with slight resistance and the tension test collar can be rotated by hand while holding the rod stationary.
The sway brace should be in the neutral position when the system is hot and operating, at which time the tension test collar should be hand tight. If it is not, the sway brace should be adjusted to the neutral position by use of the load coupling. The screws in the tension test collar need not be loosened, since they serve only to secure it to the load coupling.
These big-ton constant spring supports with Bronzphite® slide plates were designed for a 400 KTA light oil processing and utilization unit in Southeast Asia. The constants are designed for high loads and utilize self-lubricating bearing plates consisting of high-quality bronze and graphite-filled grooves. Bronzphite® can be used where temperatures are up to 1100°F and for high loads, low-velocity applications, and in places where the use of oil or grease is undesirable or unfeasible.
PT&P custom-designed and manufactured a total of four big ton constant spring supports w/ Brozphite® slide plates for a 400 KTA light oil for a processing and utilization unit at one of the largest of largest oil refineries in China. In US refineries, crude oil still makes up a majority of what is produced today:
These constant assemblies were fabricated from carbon steel and hot-dipped galvanized for extra protection against corrosion. The bronze plate acts as the bearing surface, supporting heavy loads, while the graphite inserts provide a solid, oil-free sliding surface. They are designed for operating temperatures up to 1100°F and an operating load of 187,393 lb., with 1-1/2″ total travel. It is through the combination of high-strength bearings and impregnated graphite that it is an ideal environment for maintaining excellent wear resistance and durability under severe operating conditions. Load and travel testing was performed prior to shipment.
For this particular crude oil production and mining facility, we also supplied other key products from our portfolio, including variables, snubbers, sway braces, and sway struts. Petroleum refineries change crude oil into products such as jet fuel, gasoline, polypropylene, polyethylene, propane, sulfur, carbon black feed, and diesel that can be used for transportation, heating, feedstocks for making other chemicals, generating electricity, renewable energy, and paving roads.
As an industry leader in the oil, gas, and petrochemical industries for over 47 years, we specialize in designing pipe supports, expansion joints, and insulated supports for unique applications involving both products readily available and products not readily available. Our products are used in the CDU (crude distillation units), hydrocracking units, RFCC (residual fluid catalytic cracking), naphtha hydrotreater, hydrodesulfurization units (also known as alkylation units), and sulphuric acid regeneration (SAR) units in refineries.
PT&P REF. ORIGINAL POST 09252017
How a New Design was Developed During an Emergency Shut Down
Piping Technology & Products designed and manufactured new pipe supports for high-temperature pipelines at an existing power plant in August of 2002. This new design was the product of a customer’s urgent need during an emergency shut-down and the unique pipe support requirements. The original large-bore pipe supports on this high-energy pipeline were not optimally designed for the key operating conditions and as a result, failed to support the pipelines during their thermal movements. The previously supplied OEM pipe supports did not prevent (or insulate) heat transfer from the pipelines to the supporting pipe rack steel. These issues led to the plant shut down due to safety and operational considerations by the client and we were called to help.
PT&P was called in after the original supports failed again. Upon our field service technicians’ inspection, we recommended a new design brought on by the unique requirements of installation and time constraints. The power plant was in critical condition and needed a specialized minimum downtime “plan-of-action.” PT&P’s engineering and manufacturing teams worked quickly on the new design.
Engineering utilized FEA to both design the plate material and thickness required to support the various loads for the new pipe shoe and calculated the required frictional clamping force for line temperatures ranging from 650°F to 1100°F. The new supports were then manufactured on an expedited basis, supports were on-site for the client in less than 2 weeks from when the PO was placed. Our field service team traveled to the plant location and removed the failed OEM supports, and installed the newly designed supports which are still in operation today, and have replaced other OEM supports throughout their facilities nationwide.
Because the elevations of all the piping were fixed, PT&P had to develop a pipe support design that would dissipate heat and protect the PTFE 25% glass-filled slide plates (installed beneath the pipe shoe to reduce friction) from thermal damage by utilizing a design concept called “Natural Draft Air Cooling.” Natural Draft Air Cooling has several advantages over previous designs:
- Since the insulation does not carry any mechanical load with the new design, insulation material can be chosen solely based on its thermal properties. In this particular case, cyclic loading had caused insulation failure in the previous design. This problem was now alleviated.
- The new support provides effective restraint for multiple components of loads, X, Y, Z, Rotational, and Translational dependent on the location. In particular, Axial and Torsional loads are readily accommodated. These types of loads usually present difficulties for supports that rely on insulation to support a given load.
- The newly designed supports are easily installed in the field by attaching them to the pipe with bolted pipe clamps. Thus, there is no field welding.
PT&P REF. ORIGINAL POST 10102017 / Technical Bulletin 2009
These screen guides were custom fabricated for a cooling tower at a chemical plant in Texas. These anchor bars are used to secure the screen guides to the concrete. These screen guides are 10″ in width and are 42″ in length. All components were completely fabricated from A36 carbon steel with a galvanized finish. Standard quality control inspections were performed before shipment.
Many plants, such as power, petroleum refineries, metal processing, and other industrial facilities are designed to use open recirculating systems utilizing cooling towers for heat transfer from condensers and other heat exchangers through a process called “latent heat of vaporization.”
Within these cooling towers, screen guides are used in a gravity-flow distribution system where supply water flows or cascades down over successive offset levels of horizontal screens or splash bars into a basin. These guides provide a means by which screens or splash bars are supported from a concrete structure. The screens are intended to lower the temperature of water by causing the water to spread over large areas to promote maximum exposure to airflow as it cascades from the top of the tower into the lower basin. One side of the guide provides a “slot” by which screens or other types of “surfaces” can be installed. The other side of the guides are fitted with bent “strip anchor bars” similar to those used for embed plates. As a manufacturer of embed plates, we also supply these for mining facilities, semiconductor plants, wastewater treatment plants, or any construction site where there is steel attached to a concrete panel or slab.
PT&P REF. ORIGINAL POST 04102017
PT&P custom-designed and manufactured over 150 variable spring supports for a furnace application at an ammonia plant. The ammonia plant was the largest single train plant of its kind in the world for the leader in mineral-based commodity and specialized fertilizer production. As an important base to material for fertilizers, ammonia helps put food on the table as the engine of plant growth. Over 85% of anhydrous ammonia is used as fertilizer for the three primary nutrients of fertilizer: nitrogen, phosphates, and potash. The plant and the EPC for which these were designed and manufactured were in Europe highlighting Piping Technology and Products’ robust international footprint in the marketplace for over 47 years. We serve over 90% of the countries in the world covering almost all continents. Outside of use in the fertilizer industry, ammonia is positioned to have a key role in our renewable-based, lower carbon footprint hydrogen economy supporting on-board hydrogen carrier for fuel cell activities given its high capacity for hydrogen storage based on its molecular structure.
These furnace springs are fabricated from carbon steel and painted with a red-oxide primer to help prevent corrosion. We also designed and manufactured 304 stainless steel pipe clamps to attach the furnace springs to catalysis tubes within the furnace. They are designed to support a cold load of almost 3,000 lb./in. while operating in an area where temperatures are higher than ambient. There were a total of 173 assemblies fabricated for this project, 152 variable hangers, 3 constant spring supports, 6 ball joint rigid struts, and 12 rigid rod hangers. Special load tests were performed before shipping.
PT&P REF. ORIGINAL POST 08072017
|Type:||Constant Spring Supports|
|Size:||35-7/16″ Height & 75-3/4″ Length|
|Material:||A36 Carbon Steel with HDG | 304 Stainless Steel|
|Design:||9″ Total Travel at 979°F | Operating Load 6,183 lb.|
|Testing:||Hydro tested at 6,744 lb.|
These 200 U-Type constant spring supports with slide plates were designed by PT&P for a plant in Texas. They are fabricated from A36 carbon steel with an HDG finish and are typically designed for vertical movement only. However, when there is lateral or axial movement in the piping system, slide plates can be used in conjunction with these constants. In this instance, graphite slide plates are bolted to the constant’s load flange and used with an upper slide plate manufactured from 304 stainless steel with a mirror finish. The upper slide plate can be welded to the base of a pipe shoe, trunnion, or the saddle of a pressure vessel. Each of the constant spring dimensions are 35-7/16″ in height and 75-3/4″ in length. They are designed for a piping system with 9″ of total travel at 979°F and an operating load of 6,183 lb. Each of these units were load tested to meet the hydro test load of 6,744 lb. before shipment.
Products such as these are used in many different kinds of plants all over the world including refineries, renewable diesel plants, chemical plants for operations such as propane/propylene splitter units, and power plants. We have the ability to custom design and manufacture constants for specific loads and various environmental conditions. A point to note, we provided similar constant spring supports supporting loads over 150,000 lb. for crude oil processing at one of the largest refineries in the world just last year (view this project). Petroleum refineries change crude oil into products such as jet fuel, gasoline, polypropylene, polyethylene, propane, sulfur, carbon black feed, and diesel that can be used for transportation, heating, feedstocks for making other chemicals, generating electricity, renewable energy, and paving roads.
PT&P REF. ORIGINAL POST 01122018
PT&P supplied F-type variable spring supports for pipeline 1150km long carrying various kinds of crude and refined products including gasoline, diesel, and jet fuel. The expansion tripled the capacity of the current line allowing for it to carry 85% of what is transported through British Columbia increasing oil tanker capacity at the terminal seven times.
The spring supports are designed for small movements and operating loads ranging from 15,679 lb. to 19,688 lb. The housing is fabricated from A-36 carbon steel, hot-dipped galvanized, and then painted with 3 different coats (primer, intermediate, and topcoat) of paint to protect against the harsh Canadian winters while providing long term protection against corrosion. These variables will include PTFE, 25% glass filled, slide plates welded to the top of the load flange to allow for translational movement. Each spring is load tested and then preset to the specified installed load and inspected for quality assurance before shipment.
For this particular project, the PT&P team worked with the client through the client’s six-month bidding process on the project. Our unique combination of experience, engineering expertise, and production knowledge enabled customers to secure the project. PTP addressed coating considerations, technical queries, and met the demanding delivery needs of the project. PT&P’s turnaround time from PO receipt to the material on-site was 10 weeks.
Sweco Fab, Inc., a division of PT&P, fabricated a variety of spectacle blinds for a leading solutions provider. The spectacle blinds are fabricated from A516-70 carbon steel and coated with PTFE, 25% glass-filled material. The pipe sizes ranged from 2″ to 20″ diameter and all blinds were fabricated per ASME B16.48 code. The function of a spectacle blind is to allow a line to be in either full shut-off mode or full flow mode, depending on which side is being utilized.
Spectacle blinds can be made of various materials such as carbon steel (ASTM A105), stainless steel (ASTM A182 F304, F304L, F304H, F316, F316L), alloy steel (ASTM A182 F1, F11, F22,), duplex Stainless steel (UNS S31803, UNS S32750), nickel alloys (Monel 400 & 500, Inconel 600 & 625, Incoloy 800, 825, Hastelloy C22, C276), and copper alloys (copper, brass & gunmetal). PT&P has manufacturing capabilities to handle multiple materials in our facility and our engineering teams have deep experience in designing with them (View section on Metallurgy).
In this application, the line blinds and spacers are coated with Fluoropolymer Coatings which allow for lubrication and controlled friction, wear resistance, heat resistance, nonstick and release properties, and corrosion protection. The coating enables a smooth, hard, slick coating that provides excellent corrosion and chemical resistance. Other benefits of fluoropolymer coatings include reduced friction, resistance to galling, non-stick, non-wetting, electrical resistance, and abrasion resistance. Spectacle blinds are a lower-cost alternative to double block and bleed valves where OSHA requires positive isolation of piping segments for safety reasons. Spectacle blinds are installed in the inlet and outlet of static and rotary equipment, in bypass lines, at unit battery limit, and where double isolation is required for high-pressure lines.
PT&P manufactured sway struts for one of the largest LNG (Liquefied Natural Gas) operations in the world. LNG, considered a “Clean Energy” and recognized as the cleanest fossil fuel, is used in several ways in our daily lives for heating, cooking, and generating electricity. LNG is also used commercially to manufacture products like fertilizers, paper, glass, clothing, food processing, medicines, commercial vehicles in addition to generating electricity. The use of LNG helps to reduce greenhouse gas emissions which helps to combat global warming. Piping Technology & Products manufactures sway struts for use in a wide range of applications in power, refineries, chemical, and solar plants to restrain movement in tension (or X plane) while allowing lateral movement (in the Y and Z plane). These Fig. 2100-F sway struts are designed with 4″ adjustment for loads up to 8,000 lb. The pins are fabricated from 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 were enlarged to fit these component parts. The C-C dimensions are 42-1/4″, 41-1/2″, and 28″. A quality control inspection involving thread engagement and overall visual inspection was completed before shipment. In addition to sway struts, we have supplied over 3 million supports to LNG plants all over the world. PT&P has been a key supplier in LNG piping systems for almost every operator today.
Piping Technology & Products custom-designed and fabricated pre-insulated pipe supports for a high-temperature application in an HP Steam Header located in Texas. Pre-insulated supports such as these are used in several applications ranging from semiconductor plants (addressing the current computer chip shortage) to high-temperature pipelines within plants that produce biofuels and solar power. These hot shoes range in size from 2″ to 12″ in diameter and are 12″, 15″ and 18″ long, with BOP of 4″ and 6″. The supports include a thin blanket insulation used in combination with a high-density calcium silicate insulation material. Utilizing the blanket insulation in combination with the high-density calcium silicate insulation material helped to reduce the overall costs, increased the K-factor, while also reducing the weight of these supports. We custom designed these supports using ANSYS engineering simulation for temperatures up to 844°F with an operating load up to 17,965 lb. at 732 psig. A total of 95 supports were manufactured for this project, including pipe hangers, pipe shoes with insulation and trunnion supports, as well as pipe shoe clamps without insulation. All supports were visually inspected by our Quality Control department. Piping Technology & Products offers excellent manufacturing expertise and our sister company, Pipe Shields Inc., has the engineering design and experience to assist in the development of custom pre-insulated supports or advise which of our many different supports contained in our new catalog is best for your next major project.
PT&P REF. ORIGINAL POST 05302017
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
- Field Services
PT&P REF. ORIGINAL POST 03012001
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:
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
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.
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.