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Pipe Supports and Expansion Joints for Furnace Applications
1. Piping Technology & Products, Inc.
and wholly owned subsidiaries:
US Bellows Sweco Fab Pipe Shields Anchor/
Darling Ent.
Presents
Furnace Support Products
2. Presenter
Jerry Godi na
Spring Suppo rt Designer
Lead
3. PT&P and Subsidiaries
PIPING TECHNOLOGY & PRODUCTS, INC.
- Engineered Pipe Supports
- Variable, Constants, Big-tons
- Vibration Control Devices – Snubbers, Sway Struts
- Support Assembly Components – Clamps, misc. Hardware
- Pre-insulated Pipe Supports – Cryogenic/cold & Hot Applications
- Fabricated Pipe Shoes, Guides & Anchors
- Slide Bearing Plates
- Anchor Bolts, Embed Plates
IAS Certified, Member of MSS, SPED, APFA
U.S. Bellows, Inc. SWECO Fab, Inc. Pipe Shields, Inc. Fronek A/D Ent., Inc.
Metallic Expansion Joints Pressure Vessels Insulated Pipe Supports Hydraulic Snubbers
Thin-Wall and Thick-Wall Pig Launchers/Receivers Commercial & Light Industrial - Short & Adjustable Strut
Rectangular Expansion Joints Spectacle/Line Blinds Heavy Industrial – Base Mechanical Snubbers
Fabric Expansion Joints Instrument Supports Mounted Types, Anchors dynA/Damp Compensating
Slip-Type Expansion Joints ASME/Misc. Fabrication Pipe Riser Clamps Strut
Member of EJMA ASME U-Stamp & R-Stamp ISO 9001-2008 Certified ASME Nuclear Certified
5. Basic Steps in Design
Check
clearances
Furnace Spring
Select
hanger
type
Calculate
thermal
movement
of piping at
Calculate each
hanger hanger
loads due location
Determine to piping
hanger weight
locations
1 2 3 4 5
6. Furnace Springs vs. Standard Springs
Variables FURNACE STANDARD
SPRINGS SPRINGS
CONSTRUCTION - Welded design for - Bolted assembly
housing assembly - Interchangeable
- Centers the spring sub-components
coils within the housing - Standard name
and accommodates lug plate with catalog
attachments data
- Custom name plate
with test data and
identification tag
COATINGS Red oxide primer in Hot dipped
order to avoid potential galvanized. When
hazards when exposed molten zinc
Constants to high temperatures. coating melts, it
can damage
surrounding pipe
and equipment.
APPLICATION Used as a method for Designed to
load calibration accommodate
load at support
location
7. Variable Furnace Spring Supports
FABRICATION
• Minimum amount of
components
• Close tolerances among moving
components
• Seamless pipe (A106 carbon
steel)
• Painted (usually with red oxide
primer, some are painted white)
• Not galvanized (galvanize would
melt and drop below creating
more weight)
• Coil is coated with neoprene
• Coil guides (permanent and
moving)
8. Variable Furnace Spring Supports
FABRICATION
AND ASSEMBLY
• Coil being
compressed into
can to establish
lower working
range load
• Closure plate being
positioned for final
welding
9. Variable Furnace Spring Supports
CONFIGURATIONS
A-Type Variable Springs B-Type Variable Springs
• 1,520 Furnace spring assemblies for a • 251 Furnace spring assemblies
chemical plant for fertilizer production in a
chemical plant
• Total travel range from 3/4” to 2”
• Load range: 1,042 lb. to 15,512 lb.
• Load range from 143 lb. to 660 lb.
D-Type Variable Spring Assemblies
• Furnace springs for a chemical refinery
• Total travel range from 1-1/4” to 5”
• Load range from 850 lb. to 13,300 lb.
10. Variable Furnace Spring Supports
Working Range TESTING
Minimum
• Tested over the entire
working range
• Exact spring rate
determined
• Primarily set at the
“calibrated” load
position
Working Range
Maximum
Calibration Load
11. Variable Furnace Spring Supports
APPLICATION
• Hydrogen
Re-Boiler
• Manifold Piping
Support
Locations
• C-Type Variable
Springs
12. Variable Furnace Spring Supports
APPLICATION
• Radiant Coils in
Gas Vent Heater
• Variables will be
used in place of
counter-weights
13. Constant Furnace Spring Supports
FABRICATION
• Minimum amount of
components
• Close tolerances among
moving components
• Painted (usually with red
oxide primer, some are
painted white)
• Not galvanized (galvanize
would melt and drop below
creating more weight)
• Coil is coated with neoprene
14. Constant Furnace Spring Supports
CONFIGURATIONS
A-Type Constants for a Hydrogen Reformer C-Type Constants
• Load Capacity Range: • Load Range:
1165 lb. to 2260 lb. 1149 lb. to 5149 lb.
• Travel Range: • Travel Range:
13” to 14-1/2” 4.5” to 10.5”
• Dimensions: • Includes a Double
24” long Lung Horizontal
10-½” wide Traveler
51-½” high
• Horizontal Travel: 8”
• Fabricated from
Carbon Steel
D-Type Constants for a Radiant Tube Support System in a Furnace
• Custom designed to fit in a limited
amount of space inside the furnace
and provided with optional bolting
patterns for attachment to the
supporting structure
15. Constant Furnace Spring Supports
TESTING
• Tested over the entire
working range
• Primarily set at the installed
position
• Set to the load required by
the customer
• Create a test report to ensure
the correct load and total
travel required
16. Constant Furnace Spring Supports
APPLICATION
• Support furnace
standing 3 levels high
• 13 single beams
confined to limited space
will each hang 30
constants
17. Furnace Spring Supports
INSTALLATION
Procedure for Installing Variable Furnace Springs
• Securely attach spring housing to the existing structural
or foundation member
• Attach hanger rod where applicable
• Attach all related assembly hardware
18. Furnace Spring Supports
INSTALLATION
• Perform any hydro-testing
as applicable
• Remove travel stops Critical Elevation Established via
• Adjust the load indicator Built-in Adjustability of Variable
Spring Assemblies
to calibration load setting
19. Furnace Spring Supports
INSPECTION
NOTE: Furnace must be shut-down for visual inspection
Ten Point Operational Integrity Check:
Beam attachment
Beam attachment pin
Spring hanger attachment
Load flange movement
Spring coil corrosion
Check load indication for hot load
Note load deviations
Turnbuckle/locknuts
Threaded rod/weldless eye, hex nuts
Pipe clamp attachment pin
20. Adjustments / Maintenance
Adjustments: Maintenance:
• Due to inadequate support of a piping
• Spring hangers can be set to desired
system, static loads can cause
position by turning the turnbuckles/load
problems, such as:
column
– Leaking flanges
• When nameplates are present indicating
– Continued pump & turbine problems
design hot load, adjustments can be
related to bearings, seals and
made during operation misalignment.
• When nameplates are present indicating – Sagging lines and liquid trapped in low
design cold load, adjustments can be sections
made during shutdown (assuming the – Increased system stresses resulting in
supported load has not changed) potential piping failures.
21. Re-calibration / Replacement Criteria
Re-calibration:
– Spring hanger missing a name plate
– Operating load range > 15,000 lb.
– Spring is in good operating condition
– Cost of field time & equipment required is
less than the cost of new spring hanger
Replacement:
– Sign of damage and/or broken
components
– Excessive corrosion
– Equipment to be supported has been
modified/changed from its original design
22. Shutdown/Isolation Procedures
– Lines/equipment must have a temporary support while repairs
are made
– Re-install travel stops when the line is taken out of operation
(shutdown) to prevent line/equipment movement and possible
readjustment of the springs
– If re-calibration is recommended and name plate is missing, the
variable spring should be stenciled at the proper installed and
operating positions or provide these loads
– Remove spring hanger assembly
23. Future Webinars on Standard Springs
We also host more in-depth Webinars on standard springs!
Keep a look-out in our newsletters for the invitation to…
Variable Springs Constant Springs
24. Furnace Expansion Joints
General Characteristics
– Flexible junction between the floor of the furnace and the
pipe penetration openings
– Used to prevent heat loss
– Used to compensate for high temperature gradients
between duct work / piping leading in and out of furnaces
– Constructed primarily of non-metallic bellows
25. High Temp. Furnace Bags
FABRICATION
• Bag consists of multiple layers of flexible, flame
and heat resistant, impervious fabric
• Designed to operate from start up to high
temperature design conditions and expand and
contract with the varying furnace temperatures
• Our bags are nickel reinforced with a special
coating that reduces airborne fibers and increases
tensile strength
26. High Temp. Furnace Bags
APPLICATION
• Openings between the floor of the
furnace and the pipe penetration
openings can cause heat energy
loss.
• A penetration bag type seal can
prevent the energy loss during
expansion and contraction.
• The furnace bag permits movements
while providing an airtight closure to
prevent heat loss.
27. High Temp. Furnace Bags
APPLICATION
• 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 floor.
• A tapered steel coil
is installed around
the conduit inside
the bag to prevent
the fabric from
collapsing inward
during vacuum
conditions.
28. High Temp. Furnace Bags
INSPECTION /
REPLACEMENT
• Look for rips or tears in
the fabric and openings at
the seal
• Observe any damage or
corrosion of the clamping
elements
• Seal can function through
maintenance “shut-down”
cycles
• Easy to replace after
several years of operation
29. Flanged Expansion Joints
FABRICATION
• Fabric belt consists of maximum of 3 layers
• Layers can be fabricated from: Silicone,
Fiberglass, PTFE and Mineral Wool Insulation
Reinforced Aluminized
Silicone Fabric Glass Cloth
Multi-layered
Fabric Belt
PTFE Coated Silica Oxide
Glass Cloth Glass Cloth
31. Flanged Expansion Joints
APPLICATION
• Flanged
Expansion Joints expansion joints
are usually used
on the duct work
and piping leading
in and out of
furnaces
32. Flanged Expansion Joints
INSPECTION
• Check for signs of leakage or
loss of pressure
• Inspect any distortion or yielding
of anchors, hardware, bellows,
and piping components
• Observe for any unanticipated
movement of piping due to pressure
• Check guides and other movable parts for evidence of binding
REFURBISHMENT / REPLACEMENT
• The unit can be refurbished by replacing the fabric belt and using the
same metal flanges after many years of service
33. Value-Added Services
Project Stock Inventory Capabilities
At Piping Technology & Products, we can:
– Pre-build a large quantity of assembly components
– Stock full quantity of project for different deliveries
34. Value-Added Services
Engineering & Design Department
Engineering and Design
Piping, pipe support and
structural design
3D modeling technology
Pipe Stress Analysis
• ANSYS
Finite Element Analysis
• Special stress/thermal problems
• Pro/E for 3-D Part Design
• ANSYS for Mesh Generation
+ Analysis + Results Analysis
– Field Testing
35. Value-Added Services
Field Services & 24x7 Emergency Service
On-site installation guidance
On-site inspection/maintenance of pipe supports
On-site snubber inspection
A system of stock standard Items
“On-call” engineering team
Available 24x7
PT&P’s “On-call” engineering team guarantees a response time of 30 minutes
36. Value-Added Services
Technical Literature Online “Over 450 Project
Examples”
www.pipingtech.com
Pressure Balanced FEA: Plate Thickness
Expansion Joints and Pipe Stress
Fatigue Testing Inspection and
Maintenance of
Supports
37. Thank You for Attending…
PT&P Webinar: Pipe Supports and
Expansion Joints for Furnace Applications
Request a PDH Certificate at enews@pipingtech.com
Please send any additional questions or inquiries to
info@pipingtech.com
Useful Links:
• Online Quote: www.pipingtech.com/quote
• Online Catalog: www.pipingtech.com/catalog
• Technical Webinars: www.pipingtech.com/webinar
• Blog: www.pipesupportsblog.com
Notes de l'éditeur
Hello everyone, I would like to welcome you to our Webinar on Variable Spring Supports. The Webinar today is hosted by Piping Technology & Products. I am Jerry Godina and I will be your presenter. Also, if you have a question, please feel free to chat it to us during the presentation in the text box you see to the right of the presentation or if you prefer, you can ask questions after the presentation during our “Questions and Answers Session.” http://webs.purduecal.edu/civs/research/mechanical-engineering-department/hydrogen-reformer/ convert natural gas into hydrogen through a series of catalytic reactions. The combustion process in the furnace provides the heat to maintain the chemical reaction inside the catalyst tubes.
For those of you who are unfamiliar with PT&P, I want to quickly go over some background information. If you would like to know more, please visit our “About Us” section at pipingtech.com. Our parent company, Piping Technology & Products, Inc., also known as PT&P, is a member of MSS, SPED, and APFA In business since 1975, Piping Technology & Products, Inc. and its wholly owned subsidiaries (US Bellows, Sweco Fab, Pipe Shields, and Anchor Darling) offer a wide range of engineered products and services for various industries and applications. Our product line is extensive… From engineered pipe supports, expansion joints, pre-insulated pipe supports, and miscellaneous fabrication to various engineering and technical services, PT&P has decades of experience providing products and services for all your engineering and construction needs.
9500 lb. Load C-Type Constants Modified to fit in Constricted Areas Near a Furnace
Pipe Hangers are designed to control: Longitudinal weight stress in the piping system without creating additional stresses Piping system loads on equipment without limiting or reducing static loads Hanger loads on building structure And physical clearances of hanger components with piping and structure Let’s look at the basic steps in the hanger design: Step 1 is to determine the location of all the hangers Then calculate the hanger loads due to the piping weight Next calculate the thermal movement of the piping at each hangers location Step 4 is to select the hanger type and finally check all clearances
Difference - The major differences between standard springs and furnace springs are in their construction and their intended use. Furnace springs operate in much the same way as other variable spring supports. They are designed to support the pipe or tubes that are subjected to vertical thermal movement. The design changes are necessary because furnace springs are exposed to extreme temperatures. Coatings - Furnace springs are almost always coated with red oxide primer in order to avoid any potential hazards when exposed to high temperatures. Standard springs are usually hot dipped galvanized, which, when exposed to high temperatures, tends to melt the zinc coating. The molten zinc can then cause damage to the surrounding pipe and equipment. Construction - Whereas many of the standard variable spring components are interchangeable, the furnace spring assemblies are constructed from components unique to its application and intended use. The furnace spring incorporates a welded design for the housing assembly unlike standard spring housings that use a bolted configuration. The internal components of the furnace spring are designed to center the spring coils within the spring’s housing to prevent misalignment. In addition, the spring housing is modified to accommodate lug attachments on existing furnace tubing and equipment. Special fabricated casings, spring coils, and nameplates may also be used to accommodate increased travel. Design - Some furnace springs are designed in order for the spring to be used as a means to determine the loading of the catalyst tubes. In these applications, an exact spring rate is determined for each assembly. The exact spring rate (which may differ slightly from published spring rate values) can then be used to determine the weight of the tubing system in order to balance the unit.
Location of blog post: http://www.pipingtech.com/blog/2004/01/09/furnace-spring-assemblies-up-to-13000-lbs-for-a-chemical-refinery/ Pictures of them crated in shipping: W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\oct\\boxed_support_102103 KBR JOB… Jan. 2004 Job# 71755 (pic of rods) W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\oct\\rods_71755R1 Piping Technology and Products, Inc. designed and manufactured furnace spring assemblies for a chemical refinery in Saudi Arabia. Each pipe hanger assembly consists of a variable spring, rod, clevis, hex nuts, and pipe attachments. Unlike other variable springs which are designed to have bolted housings, these furnace springs are designed for spring coils with a customer specified spring rate installed in a welded housing. The sizes of these Fig. PTP-2 and Fig. PTP-4 ranged from 90-170, with a total travel of 1 1/4″ to 5″, and loads varying from 850 lbs to 13,300 lbs. Prior to the final welding, trial fit-up and cycle test were performed to ensure unrestrained movement throughout the designed travel range. The spring assemblies were then calibrated to determine the exact spring rate prior to shipping. 1,520 Spring Assemblies for a Chemical Plant PT&P recently manufactured 1,520 PTP-2 and PTP-4 spring hanger assemblies designed specifically for a furnace application. These custom variable springs have welded components as opposed to bolted components found in standard assemblies. Due to the space limitation within the furnace, the spring coils were set in a welded housing which allows for the springs to be closely oriented within a smaller spatial envelope. The pipe hanger assemblies are made from carbon steel, consisting of variable spring, rod, and riser clamp components. Instead of galvanizing, the assemblies were coated with a red-oxide primer due to the high temperature operating conditions of the furnace. This prevents the possibility of molten zinc (from the galvanizing process) contaminating the furnace tubes. The springs are designed for loads of 143 to 660 lbs. and for total travel ranging from 3/4 to 2″. Each assembly was pre-assembled to ensure free movement throughout the spring’s travel range before welding the bottom closure plate. Prior to shipment, all assemblies were calibrated to determine the exact spring rate and then were set to the customer’s designated cold load position. These springs are then located and installed into the furnace based on the spring rate.
Engineered Spring Hanger for Reformer Furnace in Venezuela Engineered spring hangers shown are being calibrated and tested at Piping Technology & Products, Inc., Houston, Texas Facility. A digital load cell is attached to the hydraulic press that guarantees calibration to the exact loads specified. The spring hanger will support the tubes in a reformer furnace destined for Venezuela. August 1993
Piping Erection for Hydrogen Re-Boiler http:// www.dormanengg.com/project.php?&page =6
Radiation Coils Gas Vent Heater http://www.vdlkti.be/?page/3315322/Coils+and+Piping+Systems.aspx http://www.tragsqatar.com/gallery/gallery.htm
Location of pics: W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\may\\j.r_constants Location of blog post: http://www.pipingtech.com/blog/2003/09/26/950-lb-load-c-type-constants/ Sept. 2003 Job #70610 (Nooter Eriksen)… found that job number on galvanized constants in the same folder FABRICATION 9500 lb. Load C-Type Constants PT&P recently designed and manufactured sixteen PTP-200 C-type constants modified to fit in constricted areas near a furnace of a chemical facility. These constants are designed to travel from 5 1/2” to 19” and are specified to carry loads ranging from 245 to 924 lbs. They were fabricated from A36 plates with 4140 pins. Due to the proximity of the pipes and other equipment, the front part of the constant frame was cut to allow the pipe to move freely. Load and travel testing was performed to ensure quality and precise performance.
http://www.pipingtech.com/blog/2006/01/04/88-constant-supports-for-a-hydrogen-reformer-plant/ These Figure PTP100-A size 40 and 51 constant supports, made of A36 carbon steel, are used to support pipeline systems. Each is 24″ long, 10 1/2″ wide, and 51 1/2″ high. These constants are capable of supporting loads ranging from 1,165 lb. to 2,260 lb. with a travel range of 13″ to 14 1/2″. PT&P specifically designed and fabricated each constant for specific dimensions provided by the customer. Standard load and travel testing was completed for quality assurance. 81599 82411 Location of pics: Location of blog post: http://www.pipingtech.com/blog/2002/05/03/c-type-constants/ C-Type Constants May. 2002 Job #____ Piping Technology & Products, Inc. designed and manufactured 70 horizontal, C-type constants for a furnace application located in Venezuela. The sizes of the Figure 200 constants ranged from 32 to 64, with a total travel of 4.5 to 10.5, and loads varying from 1,149 to 5,149 pounds. The constants are provided with a custom designed PT&P Figure 270, which consists of a double lug horizontal traveler versus a single lug. Within the horizontal travel, the constants are designed to handle 8 of horizontal movement and support a rod that remains vertical throughout pipe movement. Constants for a Radiant-tube Support System The photograph above shows a large number of specially designed constant spring supports being prepared for shipment to Chile. These constants are the key component of a reforming furnace, radiant tube support system designed for one of the world’s major engineering and construction firms. Piping Technology’s engineers designed these units to fit in the limited space available inside the furnace and provided optional bolting patterns so attachment to the supporting structure could be made even if the radiant tube support system assumed a competitor’s design. Jan . 8, 1994
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Location of pics: W:\\digital_camera\\Digital Album\\images\\digital_camera\\2003\\may\\furnace_springs Location of blog post: http://www.pipingtech.com/blog/2002/02/15/400-lightweight-vertical-constant-load-hangers/ Feb. 2002 Job #70454 MAYBE (Nooter Eriksen) for Formosa Plastics Plant (Point Comfort, Texas)… found that job number on galvanized constants in the same folder 400 Lightweight, Vertical Constant Load Hangers Piping Technology & Products, Inc. specially designed and fabricated four hundred 100-C, vertical constant load hangers for a plastics plant in Texas. The constants will be used to support a furnace standing three levels high. In the plant, thirteen single beams confined to limited space will each hang thirty constants, therefore PT&P engineers were required to design the constants to weigh less than 150 pounds. The 136-pound constants with travels of 10 inches upward and a supporting load of 950 pounds, are 33 7/8″ in height and 8 7/8″ in width. They are also supplied with shop prime, painted finish to safeguard against the extremely hot temperatures of the furnace area. In order to insure quality and proper operations of the constants, a prototype was built and tested to MSS standards.
Variable Springs to Meet Travels Needed to Support Furnace Tubes of a Hydrogen Reformer Piping Technology & Products, Inc. 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 inches to over 6 feet long. The calculated spring rate is 79 lb/sq in for an operating load of 2,804 lbs. and installed load of 3,505 lbs. The housings are coated with a heat resistant paint, which protects the spring coils from corrosion and high temperatures of the furnace area.
To adjust a spring hanger after inspection, set to the desired position by turning the turnbuckles and load column. When the nameplate is present indicating the design hot load, adjustments can be made during operation, but a cold load adjustment needs to be made during a shutdown.
In the case you want to use your existing spring support, re-calibration is an option as long as the support is a constant spring support, in good operating condition, has an operating load range greater than fifteen thousand (15,000) pounds and the cost of field time and equipment is less than the cost of a new spring hanger.
A few thoughts during shutdown: Are the lines and equipment temporarily supported while repairs are being made? To prevent having to readjust the spring, I need to re-install the travel stops. If the name plate is missing, stencil the proper installed and operating positions or provide loads for re-calibration.
87 Fabric Expansion Joints for a Furnace Application at a Chemical Plant in Texas U.S. Bellows, Inc. manufactured 87, rectangular fabric expansion joints for a furnace application at a chemical plant in Texas. The joints were designed at 11″ W.C. and 750 degrees F for ½ ” axial and lateral movements. The fabric belts on these joints are composed of three layers. They were equipped with a telescoping liner and 2″ thick insulation pillows to reduce the heat transfer. http://www.usbellows.com/blog/2002/08/30/87-fabric-expansion-joints-for-a-furnace-application-at-a-chemical-plant-in-texas/
Our engineering and design department is involved in the following processes: -Piping, Pipe Support and Structural Design -3D Modeling Technology -Pipe Stress Analysis, in which we use Caesar II -For Structural Analysis, we use STAAD II -Our engineering and design department uses Finite Element Analysis for many projects: -FEA is used for Special Stress and/or Thermal Problems -It is used in 3D Part Design -They use ANSYS for Mesh Generation and Analysis and Results Analysis -Our Engineering and Design department is also involved in Field Testing.
PT&P offers on-site installation guidance, inspection and/or maintenance of pipe supports and snubber inspection. We carry a system of stock standard items and have an “on-call” engineering team available 24x7.
Since we don’t have much time this evening, you may want to check out our website; there you will find a plethora of technical information, including different Tests we carry out, FEA Analysis, and much more.
That concludes our Webinar on Pipe Supports and Expansion Joints for Furnace Applications …. I hope everyone enjoyed the presentation and as a reminder, we have a staff of experts standing by to answer any questions you may have. You can just chat them now while in session until the end of the hour or you can also send them to us by e-mail at info@pipingtech.com
