Pipe Support Design: Considerations for Different Piping Systems

II JAY SHRI KRISHNA II

Hello friends, as we all know that Pipe supports are the unsung heroes of industrial piping systems. These critical components provide stability and structural integrity to pipes, preventing them from sagging, vibrating, or experiencing excessive stress. By strategically placing these supports, engineers ensure the safe and efficient operation of piping systems, especially in demanding industrial environments.

Pipe Support Design: Considerations for Different Piping Systems

Pipe Support Systems in
Industrial Settings

The careful design and selection of pipe supports are essential for preventing stress, vibration and misalignment, thereby safeguarding the safety, efficiency, and longevity of piping systems. The type of support required varies significantly based on the material, temperature and insulation of the piping.

In this post, we'll delve into the specific considerations for pipe support design for both insulated and un-insulated piping systems. Let's get started!

Types of Pipe Supports:

The appropriate type of pipe support is determined by a variety of factors, including pipe material, size, weight, operating temperature, and environmental conditions. Here are some common types:

1. Un-Insulated Piping:

Un-insulated piping systems, as the name suggests, lack thermal insulation. They are commonly used in applications where temperature control is not a primary concern or where the operating temperatures are relatively low. Un-insulated piping systems, typically made of carbon steel (C.S.) or stainless steel (S.S.), are used to transport fluids without the need for thermal insulation.

While simpler in design, these systems require careful consideration of factors like thermal expansion, corrosion and mechanical stress to ensure safe and efficient operation.

I. Carbon Steel (C.S.) Piping:

Carbon steel is a popular choice for un-insulated piping due to its robust nature and affordability. It is commonly employed in various industrial applications, including water, steam, and gas pipelines. The types of support using for CS Piping are:

1. Direct Support:

Suitable for smaller diameter pipes.

The pipe is directly supported on structural beams or other secondary supports.

Simple and cost-effective solution for low-stress applications.

2. Base plate Support:

Employed for larger diameter pipes to evenly distribute the load and prevent stress concentration at the support point.

A steel base plate is securely welded to the pipe, offering a solid and durable foundation for the subsequent attachment of the support structure.

The support structure (e.g., beam, column) is then securely attached to the base plate.

This design effectively mitigates localized stress and the risk of potential failures.

3. Guide Supports:

Prevents unwanted lateral displacement of the pipe, ensuring its stability and alignment.

U-bolts or guide lugs are commonly used for this purpose.

Essential for preventing pipe vibration and ensuring stability.

4. Fixed Supports:

Used to restrict all six degrees of freedom of the pipe at specific locations.

Welded beams or similar structures are used to provide rigid support.

Often used at anchor points or points of high stress concentration.

II. Stainless Steel (S.S.) Piping:

Stainless steel piping, with its superior corrosion resistance properties, is often selected for applications in harsh environments. It finds extensive use in industries like food processing, chemical engineering, and pharmaceutical manufacturing. The types of support using for SS Piping are:

1. Shoe-Type Support:

Shoe-type support is a commonly used support configuration for stainless steel piping installations.

Utilizes a steel clamp to firmly secure the pipe.

Allows for the pipe to expand and contract with changes in temperature.

2. Galvanic Isolation:

A non-conductive material (Teflon or PTFE) is inserted between the pipe and the clamp.

This isolates dissimilar metals, preventing electrochemical reactions.

Reduces the risk of galvanic corrosion.

2. Insulated Piping:

Insulated piping systems are designed to maintain fluid temperatures, reduce heat loss, and minimize energy consumption. Insulation materials, such as fiberglass, mineral wool, or calcium silicate, are applied to the pipe to create a thermal barrier.

Hot insulated piping systems are designed to transport high-temperature fluids while minimizing heat loss to the environment. They're commonly used in refineries, power plants & chemical processing industries.

The three primary types of hot insulated piping include:

I. Hot Insulated Carbon Steel (C.S.) Piping:

Hot Insulated Carbon Steel (C.S.) Piping is commonly used for moderate-temperature applications. This type of piping is often insulated with materials like fiberglass or mineral wool to minimize heat loss and maintain efficient operation.

Support Considerations for Hot Insulated C.S. Piping:

Shoe-Type Supports: These supports, with or without clamps, are commonly used to provide stability and accommodate thermal expansion.

Trunnion Supports: These supports can be used if permitted by the client or licensor. They provide flexibility and reduce stress.

U-Bolts: U-bolts are generally avoided for hot insulated piping as they can damage the insulation and restrict thermal expansion.

II. Hot Insulated Stainless Steel (S.S.) Piping:

Hot insulated stainless steel piping is ideal for high-temperature and corrosive environments. The stainless steel core provides excellent corrosion resistance, while the insulation, typically made of ceramic fiber or calcium silicate, prevents heat loss and protects personnel from burns. A thin stainless steel sheet or a suitable non-asbestos insulating material is placed between the pipe and clamp. This combination makes it a reliable and safe choice for various industrial applications.

Support Considerations for Hot Insulated S.S. Piping:

Shoe-Type Supports: Shoe-type supports are a common choice for hot insulated stainless steel piping. These supports utilize carbon steel clamps to firmly grip the pipe, ensuring its stability and preventing movement. To prevent heat, transfer and protect the clamp, a thin layer of stainless steel or asbestos cloth is often placed between the pipe and the clamp.

Welded Shoe Supports: For more robust support, welded shoe supports are employed. An S.S. pad is welded directly onto the pipe, providing a solid foundation. The C.S. shoe is then welded to the S.S. pad, ensuring a secure and durable connection.

Trunnion Supports: Trunnion supports offer flexibility in piping alignment. While they can be used, it's essential to incorporate stainless steel components, such as a short S.S. section or an S.S. pad, to maintain the integrity of the insulation and prevent corrosion.

III. Hot Insulated Alloy Steel (A.S.) Piping:

Hot insulated alloy steel piping is engineered for demanding applications involving high temperatures, high pressures, and corrosive environments. The alloy steel core offers exceptional strength and resistance to corrosion, while the insulation, typically composed of ceramic fiber or calcium silicate, effectively minimizes heat loss and safeguards personnel from potential burns.

Support Considerations for Hot Insulated Alloy Steel (A.S.) Piping:

Shoe-Type Supports: Clamp material depends on operating temperature (carbon steel or alloy steel). Insulation (ceramic fiber or calcium silicate) protects the pipe and personnel. The correct installation of clamps is crucial for maintaining pipe alignment and structural integrity.

Trunnion Supports: Offer flexibility for thermal expansion and contraction. Require client or licensor approval. Material selection based on temperature and corrosive environment. Proper insulation installation and maintenance are crucial.

IV. Cold Insulated Piping:

Cold insulated piping systems are designed to transport fluids at low temperatures. To maintain the desired temperature, the pipes are encased in insulating materials like polyurethane foam or fiberglass. This insulation layer prevents heat gain from the surrounding environment, ensuring that the fluid within the pipes remains cold.

Support Systems for Cold Insulated Piping:

Shoe type Supports: These supports utilize carbon steel clamps, to secure the pipe. To maintain the insulation integrity, special insulating blocks are placed between the pipe shoe base plate and the secondary support.

Trunnion Supports: Trunnion supports are generally avoided for cold insulated piping as they can potentially compromise the insulation integrity and introduce mechanical stress to the pipe.

3. Plastic Piping:

Plastic piping, composed of materials such as PVC, CPVC, or PEX, offers several advantages including lightweight, corrosion resistance, and cost-effectiveness. This makes it a popular choice for various applications, including water supply, drainage, and gas distribution systems.

Support Systems for Plastic Piping:

Clamp-Shoe Assembly: Due to the softer nature of plastic pipes, a specific clamp-shoe assembly is necessary to prevent stress concentration and damage. A soft PVC sheet is placed between the pipe and the clamp to distribute the load and protect the pipe.

Code Compliance:

To ensure the safety and reliability of piping systems, all pipe support designs must comply with relevant industry codes and standards. These standards, such as ASME B31.1 for Power Piping, ASME B31.3 for Process Piping, and ASME B31.8 for Gas Transmission and Distribution Piping, provide guidelines for the design, installation, and maintenance of piping systems.

Adherence to these standards helps engineers design and implement effective pipe support systems that meet the specific requirements of each application.

Conclusion:

Proper pipe support design is crucial for ensuring the safety, reliability, and longevity of piping systems. By carefully considering factors such as pipe material, size, weight, temperature, and operating conditions, engineers can select the most appropriate support system.

For un-insulated piping, direct supports, pad supports, guide supports, and fixed supports are commonly used. For insulated piping, shoe-type supports and trunnion supports are often employed, with careful consideration of insulation integrity and thermal expansion. In the case of plastic piping, specific clamp-shoe assemblies with soft PVC sheets are necessary to protect the pipe from damage.

By following best practices and adhering to relevant industry codes and standards like ASME B31.1, B31.3, and B31.8, engineers can design and implement effective pipe support systems that contribute to the overall success of industrial projects.

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