Klaus was born and raised in Lingen, Germany. After receiving his Masters in
Chemical Engineering in 1977 from the Wilhelms University in Münster,
Germany, his first job assignment brought him to the U.S., where he resided
in Richland, Washington, for the past 36 years.
Besides the DST – Quality functions, Klaus is the Owner & President of
Redmann Quality Engineering Services, Inc. Primary focus of the RQES -
Consulting Business is the performance of Fuel Fabrication & Inspection
Surveillances during the fabrication of entire commercial Nuclear Fuel -
Reload Campaigns. As a Consultant to the U.S. - Nuclear Utilities, RQES
assures the product compliance to the Utility / NRC – Nuclear Fuel Design
and Licensing requirements. By review of the applied fabrication and
inspection processes, RQES verifies the adherence to all Fuel Fabricator and
Utility - Technical Specifications and Drawing requirements for the final
acceptance of the nuclear fuel.
Klaus P. Redmann In addition, as an ASQC - Certified Quality Engineer and ANSI 45.2.23 / ISO
certified Lead Auditor, Klaus performs both national, as well as international
Disc Spring Technology, LLC
Quality Systems and NUPIC Audits.
Director of Quality
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Webinar Sections
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Why are we here today?
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Timeline
Founded in
Richland, Granted US Quoting & Manufacturing
Washington Patent Disc Spring
2007 2014
Entered License
Agreement with Piping
Technology & Products
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Patent
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Introduction
Sources: www.pinnacleequipments.com/oil-gas-refineries.html
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Key Objectives of
DST Support System
• Loss of production
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Spring Support Comparison
Conventional Helical Coil Support DST – Disc Spring Support
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Presenter Introduction
HOME TOWN:
New Orleans, La. USA
Currently living in Houston, Tx – Since 2012
PROFESSION:
Pipe Stress Engineer
EDUCATION
Bachelor of Science Degree in Industrial Technology
South Eastern Louisiana University, Hammond, Louisiana (Dec.1972)
CAREER
Piping Designer Rust Engineering (11/74-4/75) Baton Rouge, La.
Sr. Designer F.C. Schaffer & Associates (4/75-9/90) Baton Rouge, La.
Kirk V. Leonardi Piping Stress Analyst Jacobs Engineering (9/90-5/96) Baton Rouge, La.
Disc Spring Technology, LLC Piping Stress Analyst Ford Bacon and Davis (5/96-4/01) Baton Rouge, La.
Sr. Pipe Stress Engineer Bechtel National Inc.(11/01–Present) Houston, Tx.
Director of Design & Research
PIPE STRESS PROGRAMS
Simplex, Triflex, Pengs, Caesar II
3501 Exxon Pipe Stress Analysis Program
ME101 Bechtel Pipe Stress Analysis Program
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Industry Observations
Background
• As pipe stress analyst, vessel experts and designers, we realize the
importance of meeting code standards on process equipment nozzles.
Current Practices
• Meeting code allowable stresses and nozzle loading can eat into an
engineering budget very quickly.
• Redesigning piping with loops or shifting the pipe mass away from process
equipment nozzles is a costly and time consuming.
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Root Factors of Excessive
Forces on Process Equipment
o Misalignment
o Thermal Expansion
o Pipe Lift-off
o Poor Engineering Practices and Design Errors
Sources: www.pump-zone.com/seals/compression-packing/how-do-
plant-pipe-strain-problems-affect-my-pumping-systems.html
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Pipe Misalignment and Pipe
Strain Related to Pump Failure
Coupling Misalignment
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Misalignment
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Pipe Strain
Source: www.pump-zone.com/seals/compression-packing/how-do-
plant-pipe-strain-problems-affect-my-pumping-systems.html
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Thermal Expansion
“The load and stress imposed from a connecting piping system can greatly
affect the reliability of equipment. These loads, either
from expansion of a pipe or from other sources, can
cause shaft misalignment, as well as shell deformation,
interfering with the internal moving parts. Therefore, it
is important to design the piping system to impose as
little stress as possible on the equipment. Ideally, it is
preferred to have no piping stress imposed on
equipment.” 10
Source: L.C. Peng (2003, August). Hazardous Situations Created By Improper Piping
Analyses. Retrieved (July 2010), from http://www.pipestress.com/Pages/PEpapers.html
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Pipe Lift-off
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Poor Engineering
Practices and Design Errors
failures.” 14
• “Based on the accident reports, the basis of the equipment
failure and the root cause of the accidents are related to
design error, which only appeared after an accident.” 14
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Process Cost Due to Misalignment
• “A 9% impact is worth $692 per year. These costs affect the bottom line and
can be quite significant in a typical process plant with hundreds, if not
thousands, of pumps.” 8
Sources: (left) www.pipedesign.com and (middle) www. totalpumps.co.nz and (right) www.worldpumps.com
Source: Nicolas Ganzon, Manager. The Importance of Proper Pump Alignment (September 2010), from
http://www.gouldspumps.com/download_files/Technews/Winter_2002_ImportanceOfPumpAlignment.pdf
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Process Cost Due to Misalignment
Rest
25-50%
Source: www.thinkstockphotos.ca / Nicolas Ganzon, Manager. The Importance of Proper Pump Alignment
(September 2010), from www.gouldspumps.com/download_files/Technews/Winter_2002_Importance
OfPumpAlignment.pdf
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PROFESSIONAL AFFILIATIONS:
P. E. (California/Oregon/Washington); Served on ASME B31.3 committee - Oregon
EXPERIENCE
Highly experienced in the areas of process piping, pressure vessels, heat
exchangers and API process tank design used for Interstate Gas Pipelines,
Bart V. Makadia, P.E. Refineries, Chemical & Power Plants, Pulp and Paper Mills Semiconductor and
Disc Spring Technology, LLC Nuclear Industry in accordance with the ASME, ANSI, API, TEMA, AISC, UBC,
Engineer Director
DOT, OSHA and CFR codes and standards.
42 Years Professional Areas of experience in diverse process industry include: Vessels, Heat
Work Experience…
Exchangers, and API Tank design and analysis; Codes Calculation, Fabrication,
• Vessel Shop --- 2 yrs.
• R.M. Parsons – 4 yrs. Welding, Inspection, Testing and Repairing background; Stress analysis of
• Fluor Inc. –----- 3 yrs. process piping and pipe support design; Local Stress analysis of Nozzles per
• Rust Eng. ------ 15 yrs. WRC 107, 297 and Nozzle Pro; Preparation of technical specifications and detail
• Jacobs Eng. –- 4 yrs. drawings for bid inquiry; Seismic analysis, Anchor bolt, Anchor chair and Base
• Harris Group - 2 yrs.
• Willbros Co. -– 2 yrs. plate design; Tank assessment, re-building & mechanical integrity certification per
• Bechtel Inc. –-- 10 yrs. PSM, EPA & local codes; Design and fabrication of FRP and dual laminates tanks
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Code Requirements for
Nozzle Loads & Responsibilities
ASME Sec. VIII, Division 1 requirements
for nozzle loads from piping:
• Paragraph UG-22(c) & UG-45
• Problem areas that may cause
overstressed conditions - code violations
• Nozzle loads (no reinf. or hi loads)
• Geometry / flexibility / rigid piping
• Modular design or off-the-shelve vessels
• Exceeds flange rating (ASME B 16.5)
• Not properly designed or installed
• Support(s) not active - all cases (lift off)
• Not enough space for supports
• Vendor’s allowable too low
• Coordination with other group / vendors
• Poor maintenance
• PSM / OSHA Inspection – Integrity Check
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Code Requirements for
Nozzle Loads & Responsibilities
ASME B31.1 Code Requires Piping Layout, Piping Design
and selection of Supports Prevent the Following:
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Piping and Equipment Codes
24
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Equipment Nozzle Load
Standards and Parameters
25
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Heat Exchanger Application
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Presenter Introduction
HOME TOWN:
Silver Spring, MD USA – July 1968 – July 2002
Currently, I live in Pasco, WA – Since 2002
PROFESSION:
Mechanical Designer/Support Engineer/Pipe Designer
EDUCATION
Bachelor of Science Degree in Mechanical Engineering Technology
Old Dominion University, Norfolk, Virginia (May 1997)
(Design Elements for Manufacturing)
CAREER
Mechanical Design Engineer - Howmet (Casting) Corporation,
James O. Taylor Hampton, Virginia - Responsible for design of large scale part fixtures
Disc Spring Technology, LLC for casting and machining.
Director of Fabrication Mechanical Designer/Support Engineer/Design Engineer - Bechtel
Power Corporation, Frederick, Maryland – Pipe Systems Designer
Bechtel National, Incorporated, Richland, Washington – Responsible
for nuclear piping systems, support qualification and engineering of
large scale support structures.
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Industry Safety & Process Issues
Source: www.amercianchemistry.com
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Industry Safety & Process Issues
Source: www.sublimedescaler.com
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Application of the DST
Compact Spring Support
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DST Applications & Solutions
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Advantages: Pipeline,
Pipe Bridge / Rack
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Advantages: Load
Sensitive Equipment
• Misalignment is minimized.
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Advantages: Plate &
Frame Heat Exchangers
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Advantages: Stacked
Heat Exchangers
• Substantially reduces
thermal loads on the
close coupled inter-
connecting nozzles.
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EXCHANGER
THERMAL SADDLES
GROWTH
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Vessel Nozzle Advantages
• No added space is
needed to support
pipes above the
vessel.
• The adjoining pipes
move upward with
the vessel’s thermal
DST
growth.
COMPACT • Lift-off loads are not
SPRING
SUPPORTS transmitted to the
vessel nozzles.
• A proper seal at the
vessel flange can be
maintained.
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Corrosion Failures
Corrosion due to salt air, chemical spills or VOC’s affect conventional carbon
steel spring support’s function rendering them ineffective and deteriorating
them from the inside out.
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Corrosion Free Design
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Spring Corrosion:
DST Support Replacement
Helical Spring Support Stainless Steel ‐ DST Spring Support
with Aggressive Chemical Aging with Amorphous Glass Coating
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Support Testing Results
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DST Support Tools
The DST Selection Program is based on the DST Selection Table (found in DST Catalog).
Enter the following data: The program returns the following data:
• Deflection (either + or -), • Shortest spring support size
• Operating load • Figure number
• Spring support type • Variability
• Spring rate
• Installed load
• Overall installed height
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Catalog and Support
• DST website
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This Compressor Analysis can
be Directly Compared to Pumps
DST COMPACT
DST COMPACT
SPRING
SPRING
SUPPORTS
SUPPORTS
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Compressor Station Analysis with
1 Spring at the Adjacent Elbow
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Analysis Results with
1 Spring at the Elbow
• As seen below, the Allowable Load is relatively low and difficult to meet.
• The Resultant force is the total force as seen by the compressor nozzle.
• Comparing the Resultant Force against the Compressor Nozzle Allowable
Load, the ratio <= 1.0 indicates a load greater than the governing code
allowable.
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Compressor Station with Added
Spring at the Compressor Elbow
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Analysis Results with 2nd Spring
Support Added at Nozzle
• Comparing the Resultant Force/Allowable load ratios before and after adding the
spring support at the compressor nozzle, the ratio with the spring support added
at the nozzle is less than 1 (meeting the code allowable).
• The drop in load case ratios are as great as 84% - a substantial drop in load!
• Once the load is below the code or manufacturer’s allowable load, nozzle
stresses remain low and flange seals maintain their shape.
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Stacked Heat Exchanger
without Spring at Saddles
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Stacked Heat Exchanger
without Spring at Saddles
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Stacked Heat Exchanger
without Spring at Saddles
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Heat Exchanger Comparison
with / without Spring Support
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Heat Exchanger
SPRING SUPPORT
(4 LOCATIONS)
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Heat Exchanger - Upclose
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Thank You for Attending!
• Corrosion Resistant
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Thank You for Attending!
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