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 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.
Pipe Shields, Inc., a division of PT&P designed pre-insulated pipe supports for a high-temperature pipeline at a petrochemical plant overseas. This style of insulated support is designed to be compact, easy to install and eliminate the need for field welding. The insulation is 5-1/2″ thick utilizing 18 lb. and 28 lb. pcf high-density calcium silicate. The “hot shoes” are fabricated from carbon steel and hot-dipped galvanized for corrosion protection. They are rated for temperatures from +40°F to +1800°F. Q.C. inspections and dimensional tests were performed before an expedited shipment.
Such insulated supports are used for chilled water, hot water, and steam line applications in industries ranging from pharmaceutical, semiconductor, paper mills, chemical plants, data centers, biofuels, and food processing to name a few. Piping Technology and Products, through its subsidiary, industry leader, and pioneer, Pipe Shields, has supplied to all these markets in the USA and internationally for over 45 years. Most recently, we made a large investment to automate manufacturing in our Houston plant to increase throughput and yield to support our customers’ needs for just-in-time deliveries reducing cash requirements on projects.