EXTRA SERVICES

SERVICE

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PRODUCTGROUP 9

9.0

SERVICES

Supplementary services __________________________________________ 9.1

Engineering______________________________________________________ 9.5

Field service____________________________________________________ 9.11

CONTENTS PAGE

SUPPLEMENTARY SERVICESPRODUCT GROUP 9

9.1

Special fields of application The standard designs described cover theusual range of application. For special areas,e.g. nuclear plants or offshore operations,extended measures in the question of materi-al quality or corrosion protection are requiredoccasionally. The fulfilment of special customerrequirements is guaranteed by the integratedquality assurance system. The applicablecertification is supplied with the order.

Service areasIncreasing pressure from costs through inter-national competition has led to the dispersalof service areas (outsourcing). Following thegrowing demand, LISEGA has readjusted itscapacity in the fields of engineering and onsiteservice at all locations. For support design,the use of specially developed computer soft-ware enables particularly effective support,e.g. in the 3D sector.

Standardized supplementary servicesBy way of specific supplementary services theLISEGA standard program can be adjusted toparticular needs. The field of product applica-tion is widened in this way and the LISEGAperformance package further optimised. Allthe significant supplementary services arestandardized according to the LISEGA modularsystem and cataloged in Product Group 9.

9.0 Supplementary services

9.1 Adjustment workConstant and spring hangers are set andblocked for cold load by electronic forceand travel measurement on a hydraulic testbench.

9.1.1 Storage of blocking devicesIf required, spring hangers can be suppliedwith storage points for blocking devices onthe housing (after deblocking). This is stan-dard on the constant hangers.

The LISEGA product pro-gram introduced in theSTANDARD SUPPORTS2010 catalog correspondsto current technologicaldevelopments in appro-priate supports for pipingsystems in industrial plantconstruction.

The relevant internationalrequirements are satisfiedat the highest level.

9.2 Quality management

9.2.1 Inspection reportsWhen required, inspection reports with digi-tally recorded values can be supplied asfunctional certification for constant andspring hangers and shock absorbers.

9.2.2 In service testingIn service testing for the mechanically func-tioning components of all makes can be carried out in the relevant LISEGA plants oron mobile test benches in the installation itself.

9.2.3 Material certificationThe following material certificates can be supplied on request:

9.2.4 Supplier COCManufacture and dispatch as per order can beconfirmed with a Certificate of Compliance.

9.2.5 Material certificates 2.2The material in all catalog components canbe certified by material certificates accordingto EN 10204 - 2.2 (not in US).

Compilation of component documentation. �

9.2

99.2.6 Material certificates 3.1 B for specialcomponentsComponents affected by the direct flux offorce, e.g. the springs of constant and springhangers, can be supplied with material certi-ficates acc. to EN 10204 - 3.1 B (not in US).

9.2.7 Complete traceability through CMTRThe complete traceability of material for allcatalog product components by way of sepa-rate manufacture is possible acc. to CertifiedMaterial Test Report.

9.2.8 Pre-examination documentsThe standardized products have largely beenqualified through independent authorities(TÜV or VGB) by specified type and suitabilitytests.

For special, particularly non-standardizeddesigns, pre-examination documents such asdesign drawings, parts lists, calculations, testsequence schedules and welding plans canbe supplied.

9.2.9 Stricter quality requirementsFor fields of application with stricter securityand quality requirements, such as nuclearinstallations, the quality assurance programis applied at the highest quality level. All thestages of order processing and handling fol-low recognized procedures corresponding tothe quality requirements of standard codesand guidelines such as KTA or TÜV suitabilitytests, as well as ASME Sect. III, NCA and NF.

The following aspects are particularly consi-dered:

➜ materials acquisition from approved suppliers

➜ complete traceability of material

➜ special supervision of manufacture

All sectors are fully documented.

9.3 Surface treatmentIn addition to specified, standardized surfacetreatment, extended corrosion protectionaccording to Technical Specification, Section 8, page 0.10, can be supplied.

9.3.1 Spring hangers and spring supports upto load group 9In addition to galvanizing, all exterior surfacesof components are treated with a barriercoating, layer thickness 30µm, and a dual-component acrylic-polyurethane blue topcoat,layer thickness 60µm. Total layer thickness:� 100µm

9.3.2 Constant hangers and supports, variablespring hangers from load size 9, rigid strutsand trapezes.In addition to the standard coating, all outersurfaces of components are treated with adual-component acrylic-polyurethane bluetopcoat, coating thickness 60µm. Total layerthickness: � 180µm

9.3.3 Connecting elementsThe connecting elements in Product Group 6can be supplied hot dip galvanized fromstock.

� Immersion painting

Spray painting

9.3

9.3.4 Pipe bearings and pipe clampsPipe-surrounding components can be trea-ted with a special coating on a blasted sur-face.

9.3.5 Special treatmentBesides the above-mentioned processes,other kinds of corrosion protection can beagreed upon for all products. Due to storage-related availability of standard designs,separate manufacture may be required inthis respect. This applies particularly to hotdip galvanizing.

9.4 PreassemblyIf not otherwise agreed, the componentsmaking up a shipment are packaged inbundles according to type.

For easier handling and economical assem-bly on site, individual components canhowever be supplied pre-assembled in loadchains, bundled and marked.

9.4.1 Preassembly of load chainsThe load chains are pre-assembled accor-ding to support drawings and marked withthe support position number. Constant andvariable spring hangers, as well as largerpipe clamps (bulky components), are keptseparate for easier handling and markedaccordingly.

9.4.2 Preassembly of pipe clamps and pipebearingsPipe clamp and pipe bearing halves arebolted together and supplied as completeunits.

9.5. Designation and markingIf not otherwise agreed, the componentsare sorted and packaged according to typeand marked for quantity, type number andorder number. Additional designations andmarkings can be supplied if required.

9.5.1 Designation of individual parts If required, all components can be individu-ally marked as to type, support or ordernumber.

9.5.2 Second name plateVariable spring hangers and constant hangerscan be fitted with a second name plate ifrequired.

9.5.3 Second load and travel scaleConstant and variable spring hangers canbe fitted with a second travel scale andconstant hangers with a second load scaleif required.

9.6 PackagingFor the various packaging requirementsappropriate types of packaging are available:

Load chain assembly

Load chains, preassembled, bundled and marked

9.4

99.6.1 Inland packagingSturdy wooden crates or pallets fitted withskids for fork-lifting are supplied for road orrail transport.

9.6.2 Seaworthy packagingSpecial wooden crates are used with skidsfor fork-lifting and reinforced side walls forcrane operations. The inside of the crate lidis covered with plastic sheeting to preventmoisture ingression.

9.6.3 Further special types of packagingcan be agreed upon in detail.

9.7. TransportIf required, we can take responsibility forthe logistics of shipment of goods to thesite or other destinations (FCA, FOB, etc.)

Part of dispatch section

Seaworthy packaging

Project-related order logistics

9.5

ENGINEERING, SUPPORT DESIGN

9.8 Engineering, support designBesides high quality requirements, it isessential in the planning of supports tokeep to tight schedules and economic tar-gets. At the same time, plant operatorskeep a consciously tight rein on the resour-ces required. To avoid thereby endangeringthe budgeting and logistics of entire projects,the planning arrangements are placed in thehands of suitable engineering firms (out-sourcing).

LISEGA has been a specialist for a long peri-od in the provision of the relevant facilitiesfor the execution of complex planning activi-ties. Highly qualified and experienced techni-cians and engineers are available at all LISEGAlocations. For the optimum fulfilment of all customer requirements, the differentareas are equipped with the latest, most

sophisticated software. In internationallyoverlapping projects, and whenever required,the engineering sections at the various loca-tions work in close association.

Pipe supports for complete plant systemsincluding secondary steel are conceived,planned and drawn up according to projectrequirements. On the basis of the LISEGAmodular system and decades of experience,ready-to-install load chains from structuralattachment right through to pipe-surroundingcomponent are generated from stan-dard supports. The relevant internationaltechnical codes and standards as well asparticular customer requirements are thereby

Engineering in Zeven, Germany

Engineering in Newport, TN, USA

systematically considered. For the designand dimensioning of both supports andsecondary steel, the relevant pipe systemcalculation data as well as detailed plansof the piping layout and structural factorsare taken into account.

For the effective transfer of the supportarrangements into 2D or 3D models, and toguarantee the economical preparation ofdrawings, the most sophisticated software isapplied. In addition to our own speciallydeveloped material the following standardprograms are currently in use:

➜ LICAD

➜ AutoCAD (2D-CAD)

➜ MicroStation (2D and 3D-CAD)

➜ PDMS (3D-CAD)

➜ Staad III (static / dynamic calculation of secondary steel)

➜ PSA 5 (pipe system calculation program)

➜ CAE-pipe (pipe system calculation program)

Analysis of complex support arrangements

The proper functional inte-gration of pipe supportsinto the existing pipingand plant concept has adecisive influence on thelong-term behavior of pipesystems. The same careand attention should there-fore be paid to supportplanning as to the pipesystems themselves. Inthis respect, the choice ofproduct and the availabilityof up-to-date design soft-ware has a major effect onthe quality of planning.

9.6

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LICAD drawing

CAD drawing according to customer requirements

The following engineering services are avai-lable according to requirements:

9.8.1 Design of support arrangements (loadchain designs) with LICAD:

The following data should ideally be sup-plied by the customer:

➜ pipe diameter

➜ loads

➜ movements

➜ temperatures

➜ insulation thickness, if necessary

➜ piping material

➜ installation length and position, orcorresponding piping and structural plans

➜ specifications

On the basis of these data, ready-to-installload chains are generated with the LISEGAdesign program LICAD from standard sup-ports, from structural attachment right throughto pipe-surrounding component. The designsso prepared are stored and printed out asscale drawings, including parts lists with loadand material data. As an option, locationplans and pricing details can be included withthe LICAD drawings.

9.8.2 Generation of 2D CAD drawings with-out supplementary steel

For the preparation of 2D CAD drawings thefollowing information on the drawing layout,in addition to the details in 9.8.1, is required:

➜ drawing sheet in format DXF, DWG or DGN

➜ drawing numbers

➜ location plans

As the basis for the CAD drawing, a LICADsupport configuration together with dimensio-ning, parts list and relevant adjustment datais supplied via a special interface. The drawingsheet required is inserted in the customer's

specific drawing layout. The CAD drawing is supplemented by a location plan and drawingnumber.

9.7

9.8.3 Generation of 2D CAD drawings incl.supplementary steel

As well as customer details mentioned in9.8.1 and 9.8.2, data as to dimension andposition of the steelwork is required for CADdrawings including supplementary steel(secondary steel). The CAD drawings aregenerated as in 9.8.2 but additionally sup-plemented by the steelwork required.

9.8.4 Complete planning with preparation ofCAD drawingsFor complete support planning (engineering),the following documentation is supplied bythe customer beside the data according to9.8.1:

➜ drawing sheet in format DXF, DWG or DGN

➜ drawing numbers

➜ piping isometrics

➜ piping calculations

➜ pipe plans

➜ structural plans

The planning of the support designs and thesecondary steel required is based on thedocumentation supplied. The results aregenerated as 2D CAD drawings in the AutoCAD program as described in 9.8.2 and 9.8.3.

9.8.5 Preparation of 3D models withMicroStation for PDSFor the generation of 3D models onMicroStation the pipe supports are first pre-pared as 2D models. The 2D data are thentransposed into 3D data by LICAD andtransferred via an interface into theMicroStation 3D model. The secondary steelrequired is supplemented in the 3D model.In PDS the 3D models so generated can beused for interference checks.

CAD drawing with supplementary steel

CAD drawing for complex support situation

9.8

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3D PDS display

3D PDMS display

9.8.6 Support design of 3D models inPDMSFor the design of 3D pipe system supportsin the PDMS program, the customer makesa PDMS model complete with pipe systems,steel and all structural components available.In addition, the data listed in 9.8.1 is required for the design of pipe supports.The support points, including the necessarysecondary steel, are planned and laid outdirectly in the PDMS 3D model by experien-ced designers. LICAD provides the well-triedbasis for this. The load chains generated inLICAD, transposed into 3D data, are integra-ted into the model with the aid of a PDMSinterface. Any secondary steel required canbe directly supplemented in PDMS.

Finally, an examination of possible obstructions(interference check) is carried out in the 3Dmodel. The customer receives a complete,fully checked 3D model with all plannedsupport positions and the relevant 2D draw-

ings, including parts lists. The support draw-ings can also be generated in the 3D modeif required.

2D support drawing generated directly from PDMS 3Dmodel

9.9

9.8.7 Static calculation of secondary steelincluding structural attachment loads.LISEGA provides the design report summaryfor the dimensioning of the planned secon-dary steel according to Code AISC orDIN18800.

Design of steelwork with STAAD III

This summary is supplied with the STAAD IIIstatics program.

9.8.8 Pipe system calculation In older installations it is often necessary forreasons of operational safety to renew pipesystems and supports in order to meet cur-rent standards in technology. There is ofteninsufficient documentation available offeringinformation on calculations regarding theoriginal design. If so desired, a static calcu-lation of pipe systems can be provided. Thefollowing typical load conditions per supportpoint are calculated:

➜ weight

➜ temperature

➜ static G

➜ emergency shutdown

➜ hydrostatic test

The codes ASME B31.1, ASME B31.3 andBS806 are observed for the calculations. Therelevant code is to be defined on orderingaccording to version and year.

SUPPORT REACTIONS IN KNS METER

KNT. LOADCASE X FORCE Y FORCE

STATIC SYS. = SPACE

Z FORCE X MOM. Y MOM. Z MOM.

9.10

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2D support drawings and PDS 3D modelgenerated from them

The following advantages are available to the customer whenusing LISEGA planning capacity to the fullest:

➜ economical limitation of your own capacity

➜ complete certainty of expert performance by experienced specialists

➜ fast and flexible processing of whole project from initial order through to delivery on the principle of “everything under one roof”

➜ complete and lasting computerized documentation

➜ availability of highly skilled personnel for any subsequent services required

9.11

ON SITE SERVICE

9.9 Plant serviceAdditional stress and strain caused by low-quality pipe supports during pipe systemoperation can lead to long-term damagethat considerably increases the risk of mal-function and breakdown when the plant isin operation.

Faults frequently occurring in pipe supportsare:

➜ poor support designs

➜ faulty installation

➜ incorrect load settings

➜ inappropriate instructions

➜ deficient quality of support components

A particular problem often arises in olderinstallations when variable spring and con-stant hangers are installed with springs thatare not pre-relaxed (see page 1.16 in thisrespect). Through the increasing relaxationover a period of time a growing loss of ulti-mate load gradually occurs. Load deviationsresulting from this can lead to impermissibleadditional stress in sensitive areas, e.g. atconnection points. Timely inspection in theplant can contribute to the prompt identifi-cation and elimination of critical stresses.

The operational safety ofpipe systems and thereforethe availability and longlife of the plants is depen-dent to a large degree onthe condition and functionalcapacity of the supportsemployed.

To avoid costly damageand operational breakdownthe regular inspection ofthermal movement inpiping systems and thecondition of supports -especially in older installa-tions - is urgently advised.

Specimen of a hanger check listfrom a plant

Checking piping movements

For this special service LISEGA offers theresources of an internationally leadingmanufacturer maintaining a team of quali-fied and experienced specialists at all grouplocations.

This team inspects the thermal movement inthe piping system and checks the supportsystems. They produce comprehensivereports and provide the appropriate recom-mendations for a solution. Special softwareis implemented for the presentation anddocumentation of findings.

The service team is expressly trained for theexecution of specific services in the field ofpipe supports and works strictly accordingto the guidelines laid down by qualitymanagement and the relevant safety stan-dards.

9.12

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Graphic display of piping systemmovements

Discussion on findings and observations in pipesystems inspected.

Testing constant hangers on sitewith a mobile test bench.

The range of services includes the followingperformance sectors:

9.9.1 Inspection of pipe supports

➜ inspection of general condition of pipe supports

➜ load and travel checks for spring supports

➜ function testing of constant and variable spring hangers with mobile test equipment at the plant or on stationary test benches at a LISEGA facilitay. The findings are automatically recorded.

9.9.2 Inspection of piping movements

➜ inspection of the general condition of the piping itself and if necessary the geometri-cal positioning.

➜ checking of piping system for unrestricted freedom of movement in all three planes.

➜ determination of vertical movements at all support points, and in all three planes at piping connections and selected points.

9.9.3 Design of supports at the plant

➜ design and planning of pipe supports in the event of renewal and modification in older installations

➜ measurement work at the plant

➜ solving problems posed by restricted space

➜ design of pipe supports with LICAD, EASYSTEEL and AutoCAD

➜ preparation of parts lists and material data

9.9.4 Supervision of construction, installationand commissioning

➜ material reception and control

➜ organization and administration of warehouse stocks

➜ pre-assembly and arrangement of completesupport configurations

➜ installation of supports at the designated points

➜ supervision of installation of piping systemsinto the supports prepared

➜ inspection of the system as to correct installation according to drawings and installation and operation instructions

➜ deblocking and commissioning the supportsaccording to an agreed procedure

➜ load and travel checks according to require-ments after commissioning

➜ inspection for freedom of movement of the pipe system in all three planes

➜ later regulation of the hangers in the event of any load differences detected

➜ function testing after dismounting and documentation of results

➜ dismounting of shock absorbers and inspection of individual components for wear or damage

➜ exchange of all seals and hydraulic fluidas well as other components with noticeable wear

➜ final function testing in line with test program and according to relevant specifications

➜ reinstallation at the plant

➜ preparation of complete final documen-tation

The LISEGA on-site service spectrumapplies especially to the use of pipe sup-ports and their effect on pipe systems. Oncorresponding utilization, the LISEGA servicepackage provides a valuable contributionto the functional safety and long life ofcomplex pipe systems.

9.13

9.9.5 Maintenance, inspection and checkingof shock absorbers

➜ visual inspection to identify signs of possible functional disorders

➜ function testing on mobile benches at the plant or on corresponding testing facilities at the works

➜ installation and dismounting, with sub-sequent transportation to the testing facilities

➜ the function testing with corresponding electronic documentation of findings can be carried out for all makes

9.9.6 Servicing of shock absorbers afterlengthy operational use or after overloa-ding

➜ dismounting of shock absorbers and documentation of external state and environmental conditions

Testing PSA shock absorbers atthe plant with a mobile LISEGAtest bench.

Check on correct installation Supervision of support installation