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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 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.Read 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.Read More
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.
|Type:||Variable Spring Supports|
|Size:||Rod Diameter 2” / Casing 8′ long & 3 1/8” Diameter|
|Design:||Operating Load 31,563 lbs., Installed Load 29,000 lbs., 0.82″ Downward Movement|
|Testing:||Standard Load & Travel Tests|
PT&P designed two standard PTP-4 size 210 A-type variable spring supports for a Process Power Plant in Oklahoma. The springs are fabricated from A36 carbon steel and with a hot-dipped galvanized finish. The springs are designed to accommodate a Hydro Test Load of 34,000 with operating Load of 31,563 and installed Load of 29,000, movement of 0.82″ downward. A Standard Load and Travel test was conducted on the variables prior to shipment. The springs utilize a rod diameter of 2” and the spring casing 8′ long and 3 1/8” in diameter.Read More
|Type:||Big Ton Spring Supports|
|Size:||42″ x 24″ x 26 1/2″|
|Design:||94,261 lb. Load & 0.085” Movement|
|Testing:||Standard Load Tests|
PT&P custom designed big ton spring supports for a propane dehydrogenation application at a chemical plant in Texas. The components within this assembly include the spring housing, coils, name plates, pressure plate, and load indicator. While both assemblies measure 42” L x 24” W x 26-1/2” H, it was modified based on independent specifications for operating loads and movement to accommodate a load of 94,261 lb. and 0.085” of movement. This type of support is ideal for applications, such as supporting pressure vessels that combine very heavy loads with thermal expansion because of the stability they provide. The big ton was tested in the load cell to insure proper operation throughout the entire working range of the coils.Read More
PT&P fabricated PTP-6 G-type variable spring supports for a coker replacement project in Kansas. The variables are comprised of two standard spring housing joined together with an intermediate bridge assembly. The bridge assembly is customized to match existing site conditions which allows for use in applications with limited space or interferences. They are 50″ in length, designed for an operating load of 15,000 lb. and fabricated from carbon steel with a hot-dipped galvanized finish. All variable assemblies underwent standard load and spring testing prior to shipment.Read More