Rilco is able to provide almost any type of steel fabrication — from un-insulated pipe shoes, pipe anchors and hold down clamps, to structural supports. This is possible because we utilize four different steel cutting systems that each provides certain benefits for various situations. By having several of each type of cutting system available at our facilities we are better able to meet our clients’ steel fabrication needs.
Plasma Cutting System
This machine is the lowest in purchase price and also maintains the lowest operating cost than alternatives. It has the fastest production rate (anywhere between 60-220 ipm), but the lowest cut edge quality and lowest cut part precision. However, to ensure top-quality products from Rilco, we use the highest quality plasma cutting machines available that utilize the latest technologies and are engineered for high torque and high resolution.
Waterjet Cutting System
The waterjet system is mid-range in regard to purchase cost, but has the highest operating cost compared to alternatives. Waterjets have the slowest production rate (anywhere from less than 1 to 15ipm), but maintain the highest cut edge quality, as well as the best cut part precision with no heat distortion. It also is the most flexible when it comes to the materials it is capable of cutting.
Laser Cutting System
Compared to the Plasma and Waterjet cutting system the laser cutting system comes in at the highest purchase price and mid-range operating cost. The laser system produces at a slower rate than the plasma (between 20 to 70ipm), but is a close second when it comes to its cut edge quality as well as the cut part precision. There is a small chance the laser can cause heat distortion and is strictly limited to metalics, some plastics and fiberglass, and some fabric.
Oxy-Fuel Cutting System
This cutting process rapidly oxidizes the steel in an exothermic reaction and is widely used for cutting steel of all shapes and sizes. Oxy-fuel cutting is done in three steps:
(1) Preheat – steel is heated to kindling temperature (1800°F) at which it readily reacts with oxygen
(2) Piercing – once the steel is at temperature a jet of pure oxygen (cutting oxygen) is used to pierce through the plate of steel
(3) Cutting – when the cutting oxygen finally reaches through the thickness of the plate, the torch will move at a constant speed, ultimately forming the necessary cut Low carbon steel and some low alloys can be cut with this process since they contain oxides with a lower melting point than the base metal. Metals that form an oxide with a higher melting temperature than the original metal being cut cannot utilize this process.
Rilco pipe supports are designed to withstand the process application load as well as the additional load caused by the process pipe temperature. The supports are installed with the initial preload on the bolts, which increases with rising temperature.
This experiment was performed to witness the actual forces exerted by the Belleville washers, as well as the deflection, both at ambient process operational temperature.
Rilco Performs extensive research and experiments on every product before it is used in the supports and supplied to our customers. Every product has to go through certain tests to ensure the products meet Rilco’s quality standards. Thermal Efficiency tests of insulations are also performed as a part of quality assurance. To provide our customer’s with the best products, Rilco has performed Thermal Efficiency Comparison Tests between two similar types of line insulation and pipe support insulation.
Two pipe line insulations were tested against each other in the exact same manner and conditions to eliminate any discrepancies that could affect heat loss or the test results. Each test was performed with two different pipe line insulatons. Three heating elements were connected to a 480 Voltage AC power supply, insulation was then installed on the pipe. The pipe was then heated to 650oF. An Acuvim II Series Power Meter was used to measure the energy used to maintain the temperature. To monitor the pipe temperature and the outer temperature of the insulation six thermocouples were used in different locations. The same procedures were followed in each test and the energy consumption was monitored.
Temperature of six thermocouples.
We recently provided several Rilco Cam Roller (RCR) constant spring support assemblies to a local propane plant. Besides the spring hanger, the assembly included a hanger rod, forged weldless eye nut, and an insulated pipe support with a heavy duty 2-bolt clamp. The high temperature insulated pipe supports included calcium silicate insulation material with high density structural inserts, to help support the pipeline load, and hot dipped galvanized carbon steel outer cradles.
These RCR single unit constants are Type E constants that will be installed with field fabricated support beams. These particular constants require auxiliary brackets on either side of the RCR assembly for support. This arrangement is most often used when little or no space exists below the support structure.
This type of constant has no top mount connection, but instead relies on the side brackets for support and transfer of force to the support structure.
We recently manufactured calcium silicate pipe shoes for a combined cycle power plant. These pipe supports are fabricated from carbon steel and include calcium silicate insulation. They will be utilized on a high temperature pipe line of 1075 degrees F. The pre-insulated pipe supports are designed for a 12″ pipeline and include 6″ of insulation.
These particular pipe supports are designed for a main steam piping system and for a load of 1500 lbs. The calcium silicate pipe shoes are custom fabricated for a special guided application that was specified by the customer.
We recently fabricated reactor outlet pipe stands for a local chemical plant. The stands were a custom fabricated design provided by our client to be utilized as a maintenance tool in their facility.
The carbon steel pipe stands incorporated four hydraulic jacks. When the unit is rolled into place, it would function to elevate the pipe section and valves, remove the section, allow them to perform the necessary maintenance, then roll the piece back out to service in the field.
The fabricated pipe stands measure 54″H x 62″W x 56″L and support valves or piping sections up to 48″ in diameter.
We have experience fabricating a wealth of custom designs from fabricated steel, to unique pipe supports solutions and vibration control devices.
Do you see a need for a custom fabricated design for your upcoming project?
I’d like to send my warmest wishes to you for the absolute best holiday season and very happy and prosperous new year in 2019. We are incredibly grateful for your business in 2018. We cannot wait to serve you in the coming year with an even higher level of excellent customer service while providing you with ideal pipe support solutions for your applications.
Do you have a job coming up that requires pre-insulated pipe supports? We provide a high quality support fabricated from carbon steel and Foamglas® insulation that is ideal for high temperature, low-temperature and even dual temperature pipe lines.
These Foamglas® pipe supports shown below were recently fabricated for a project in California. Some of these pipe shoes will be utilized as slides, others as guides and the remainder as anchor supports along the pipelines. Over 500 Foamglas® pipe supports were fabricated for this particular job in a range of pipe sizes from 2.5 inches up to 10 inches. The insulation thickness ranges from 2 inches up to 4-1/2 inches with the maximum length of the supports being 18 inches. They are reinforced by structural insulating inserts that support the load on the pipe. The superior quality of the Foamglas® insulation provides for a 100% moisture impermeable, non-combustible, non-absorbent, corrosion resistant insulation option. This insulation is also resistant to vermin, microbes and mold.
Foamglas® pipe supports are an optimal choice for applications such as cryogenic systems, chemical processing systems, and above and underground chilled water piping.
We look forward to serving your pipe support and fabri
We recently manufactured a wide variety of spring supports for a local propane dehydrogenation plant including these C-Type Figure 81H horizontal constant spring hangers shown below. These spring supports are designed for a 900 lb. load and 11.4″ of total travel. These particular supports accommodate for 9.5″ of downward movement of the piping system at their specific location in the plant.
These C-Type constants are manufactured using two (2) lugs to accommodate attachment to the building structure and allowing for the use of various types of attachments. They will be shipped with 5/8″ diameter hanger rods which will be attached to vessel lugs using lock nuts in the field. On this job, the customer sent a 3D structural/plant layout and Rilco was able to structurally place the constant to avoid existing structure contact. Custom designed lugs with modified lengths were incorporated into the design to accommodate interference from the surrounding structures.
Do you see a need for constant spring supports for your upcoming project?
We recently manufactured a wide variety of spring supports for a local propane dehydrogenation plant including these C-Type Figure 81H horizontal constant spring hangers shown below. These spring supports are designed for a 900 lb. load and 11.4″ of total travel. These particular supports accommodate for 9.5″ of downward movement of the piping system at their specific location in the plant.
These C-Type constants are manufactured using two (2) lugs to accommodate attachment to the building structure and allowing for the use of various types of attachments. They will be shipped with 5/8″ diameter hanger rods which will be attached to vessel lugs using lock nuts in the field. On this job, the customer sent a 3D structural/plant layout and Rilco was able to structurally place the constant to avoid existing structure contact. Custom designed lugs with modified lengths were incorporated into the design to accommodate interference from the surrounding structures.
Do you see a need for constant spring supports for your upcoming project?
We recently manufactured these PyroWrap pipe supports in a wide range of sizes. The supports are fabricated from carbon steel and Pyrogel® insulation material. They include Belleville washers to maintain clamping forces during thermal pipe expansion or contraction. These pre-insulated pipe supports range in size from 1/2″ diameter to 144″ diameter.
The photo below shows a large 60″ diameter PyroWrap pipe guide. It includes special powder coated springs, to ensure consistent clamping force at all temperatures, and stainless steel slide plates on the bases. Additionally, the guides include custom ultra-high molecular weight (UHMW) slide plates. The guides are meant to restrain movement laterally and allow for axial movement of the support. Due to the size of the pipe guides, Belleville washers (as used on the supports above) would not have been feasible for this application. These 60″ pipe guides are designed for very large loads and have uplift restraints incorporated into the design to eliminate the possibility of overturning.
There are various benefits to using pre-insulated pipe supports. The Pyrogel® insulation, in this case, is layered to the matching thickness of the adjoining process line insulation to ensure a proper field fit and provide seamless transitions from the support to the line. The use of Pyrogel® insulation minimizes the chances for corrosion under insulation (CUI).
Pre-insulated supports also eliminate temperature fluctuation at the support point of process fluid lines. Ultimately, they save money through energy savings by reducing overall heat losses as well as eliminating labor in the field such as welding to the pipe and expensive and cumbersome post weld heat treatment processes. These units are shipped completely assembled and ready to be quickly installed in the field. Do you see a need for pre-insulated PyroWrap pipe supports for your upcoming project?
We recently shipped out this pipe rack for a computer manufacturing facility on the West Coast of the United States. The pipe rack will be utilized to support the pipe lines throughout the plant. It is manufactured entirely from carbon steel and measures 11′-9″ in width, 6′-10″ in depth and 14′-10″ in height. The assembly, shown below, weighs approximately 14,000 lbs.
The photo below shows the pipe rack assembly being prepared for shipping. The complete fabricated carbon steel support was hot dipped galvanized and reassembled prior to shipping. Rilco has years of experience providing custom fabricated steel designs from our customers’ drawings. Be it large or small, Rilco is also up for the challenge of designing and providing a unique solution for a wide variety of applications that you may have.
Do you see a need for steel fabrication for your upcoming project?
Rilco recently manufactured these big ton spring supports for a local refinery. These springs will be used in sets of four to support a large vertical vessel. The springs accommodate for the movement of the vessel due to thermal contraction and expansion. The big ton springs include 1′-8″ square Teflon® slide plates, bonded to the carbon steel plate, to allow for movement on the surface of the support. They also include powder coated spring coils and galvanized spring casings.
Fabricated primarily from carbon steel, the big ton springs measure 2′-6″ wide and 3′-2″ in height. The hot load (operating load) for the springs is 210,000 lb. and the cold load is 240,000 with .33 inches of upward movement. Our manufacturing facility has in-house spring setting capabilities up to 400,000 lbs.
Do you see a need for big ton springs for your upcoming project?
We are proud to announce the opening of Rilco Asia (Thailand) Co., Ltd. Rilco Asia is based in Rayong and will supply the full range of high quality Rilco Manufacturing Pipe Supports and fabricated components specifically for the Asian Market.
As a customer focused organization our number one goal is to provide our clients with complete satisfaction and it is our company objective to exceed customer expectations. We plan to provide our valued customers around the world with the same upmost quality of services and products from our new state of the art manufacturing facilities in Rayong, Thailand.
Inside the New Rilco Asia Facility (Above)
With over 5,500 square meters of shop space, the new Rilco Asia manufacturing facility is now open and running. The first job has been successfully completed, and it included several low temperature polyurethane pipe shoes for a local customer. With this new facility, Rilco is able to be more competitive in price and delivery for your overseas projects while providing the same high standard of customer service.
Polyurethane Foam for the Production of Cold Pre-Insulated Pipe Supports
Our engineering team at Rilco Asia works to the same industry proven standards as we do here at Rilco USA and utilizes the latest software packages in which they create economical, yet superior quality products. The engineering department’s concise calculations and the company’s high expectation of quality are assured through vigorous testing and extensive Research and Development.
Do you see an opportunity in the near future for which our new Rilco Asia facility would be an ideal option for your project?
Rilco manufactured these polyurethane guided pipe supports for a local LNG project. The insulation was designed according to the thickness and layering of the process line insulation to ensure an optimum field fit. The proper union of the pipe support insulation and line insulation helps to eliminate condensation, and associated field corrosion problems, along with temperature fluctuation of process fluids at the support point. These polyurethane pipe supports are designed for low temperature environments down to -350 degrees F (-212°C).
The polyurethane guide supports for this particular job ranged in size from 2″ to 24″ in diameter. They are designed for lateral loads ranging from 156 lbs. to 10620 lbs. and vertical loads from 312 lbs. to 21240 lbs. This four way guide includes engineered Belleville washer counts and installation heights to accommodate thermal expansion and contraction of the pipeline.
Rilco manufactured these triple upthrust cam roller constants for a refinery expansion project in Louisiana. They were provided along with sway struts, variable springs, and pipe support hardware. The RCR constants were designed for an operating load of 52,115 lbs. and for 1/32″ of downward travel. The constants were based upon a competitor design, and Rilco provided a direct equivalent to the customer with matching loads, travel ranges and dimensions.
Slide plates were custom installed on top of the load plate to allow for movement of the pipe during expansion and contraction. The cam roller constants shown below were custom designed for a furnace application in Europe. Every assembly was laid out for QC to make sure it assembled and functioned properly. The corresponding hardware, visible in the photo, was manufactured for supporting the pigtails off the furnace tubes.
Some of the benefits of our RCR constant components are that we use stainless steel pins, galvanized cases, custom power coated components, and special coatings to reduce friction and wear. Do you see a need for Rilco Cam Roller Constants for your upcoming project?
We recently manufactured several hundred high temperature calcium silicate supports for a low humidity environment. These pre-insulated pipe support guides incorporate proprietary slide plate configurations on the shoe and on the supporting steel to accommodate axial travel. The pipe supports are designed for applications up to 1200 deg F.
These pre-insulated pipe supports are manufactured from A516-70N carbon steel and feature calcium silicate insulation with structural inserts. The calcium silicate insulation material is specially designed to be moisture repellent. They range in size from 4″ to 48″ in diameter and range in length from 12″ to 52″ long on this particular project.
The 3D model shown above, of the calcium silicate support installed on the pipe, includes belleville washers as utilized in our featured pipe support design. The belleville washers are engineered to maintain a constant clamping force throughout the pipeline temperature range to accommodate the expansion and contraction of the process pipe.
Do you see a need for Calcium Silicate Pipe Supports for your upcoming project?
Rilco recently manufactured insulation guides from polyurethane insulation as a pre-insulated pipe support solution for a low-temperature pipeline application. These supports are designed to be used on flat surfaces. They are designed for service temperatures ranging from -425 deg. F to + 275 deg F (-253 to +135 deg C). They are fabricated with carbon steel square bases that are galvanized. All exposed surfaces of the polyurethane foam are coated with a monolar mastic to protect against any moisture damage.
They are designed for ease of installation and the insulation is cut to match the line insulation layering schedule. The supports are typically attached to the low temperature pipeline using banding compatible with the line insulation jacketing. Both single layer and double layer insulation are available. Insul-guides are recommended as a low-cost solution for low-temperature pre-insulated pipe support needs.
The insul-guide model featured in the photo above is a Rilco IG-180-DL-R model. They are available with polyurethane insulation as a resting or guiding pipe support. If being utilized as a guide, the guide load is not to exceed 20% of the vertical load.
Rilco recently manufactured over 750 CryoWrap pipe supports for an LNG expansion project overseas. The supports are designed for a low temperature application and fabricated from carbon steel bases and cradles, Cryogel® Z insulation material, and stainless steel metal jacketing. The insulation material incorporates strategically placed rigidizing agents which enable the Cryogel to properly, repeatedly support the load. Without the rigidizing agents, a Cryogel only support does not possess load carrying capabilities.
The stainless jacketing is painted to provide additional protection against the harsh environment. The carbon steel is galvanized and is also finished with a two-coat paint system. The pre-insulated pipe shoe also includes a stainless steel slide plate, to be affixed to the bottom of the base, that allows the support to move along the supporting steel.
The CryoWrap pipe supports range in size from 1″ to 14″ in diameter and are fabricated with belleville washers. The belleville washers are engineered to maintain a constant clamping force throughout the pipeline temperature range. Cryogel® Z insulation has a 2 to 3 times lower k-value than cellular glass or polyurethane foam insulation. It is very durable, fire and water resistant, and helps to prevent corrosion under insulation (CUI), making it an ideal choice for an LNG application.
From all of us at Rilco Manufacturing, we would like to extend to you our best wishes for a happy holiday season and our sincere thanks for your loyalty and goodwill throughout the year.
Thank you for entrusting us with your business in 2017. We look forward to a bright 2018 and continuing our partnership by providing you with our optimum services and the finest pipe supports and fabricated steel.
We recently shipped several isolation blocks to be utilized in a low temperature application. The permali isolation blocks shown below include a steel base plate. Our isolation blocks provide a thermal break. They are designed to meet load requirements while simultaneously thermally isolating the piping system or ensuring that the structure does not fall below its design temperature.
We provide a wide range of materials including polyurethane, Micarta GE, Micarta G-10, Micarta G-10CR (both foreign and domestic), and permali for low temperature applications. For high temperature requirements, we offer materials such as Super Firetemp® and Marinite. See examples of permali, Micarta G-10 and polyurethane isolation blocks below.
The insulation for these supports can range in thickness between 0.5″ to 8″ (13 mm – 200 mm). The insulation can be utilized in a variety of configurations between the process piping and the supporting steel.
Do you see a need for isolation blocks on your upcoming projects? Please let me know how I can help you out with your pipe support and fabrication needs in 2018.
We recently manufactured custom structural steel for an LNG project in Louisiana. They measure in size 48″ x 30″ x 40″. They are manufactured from carbon steel material and designed to function as guide type supports.
The base of the supports is comprised of a flange with gussets that will allow the support to be bolted to the exterior of a vertical vessel within the plant. The pipe supports will be utilized to guide vertical pipe runs. We are able to provide steel fabrication for a wide variety of applications and from a wealth of different materials. Apart from our standard angles, channels and w beams, we have extensive experience providing structural steel per our customer drawings and needs.
See the configurations below that indicate how the above structural steel will be installed horizontally in the plant with the support designed to be tilted at a 15.5 degree angle.
We recently manufactured 12 horizontal constant assemblies for a refinery in Mississippi. The B-Type model 81-H constant spring supports are fabricated from carbon steel and are part of a complete assembly that includes pipe support hardware, a hydraulic snubber and a double bolt pipe clamp. The assemblies will be utilized to support silencers in a coker unit.
The constants shown above are designed for a 988 lb. load and 8″ upward movement. They are custom painted to withstand the costal environment where they will be installed in the refinery. The hydraulic snubbers shown below will be used to help control the movement of the silencers. They are designed for a 10″ stroke and a 2500 lb. load. The longest of the snubbers is 100″ long. They include a custom protective boot accessory to keep the coke dust off of the snubber piston rod.
The constants were all load tested for quality control prior to shipping. They were shipped with the accompanying rod hanger, forged turnbuckle, weldless eye nut, and double bolt pipe clamp. The constants include carbon steel pipe clamps that will support 3″ and 18″ diameter pipes.
We recently manufactured several fabricated pipe supports for a local petroleum refinery, including these hold down pipe clamps. The pipe clamps are fabricated from carbon steel with a Teflon® sheet bonded to the inside of the hold down strap. There is also a Teflon® slide plate bonded to the top of the carbon steel base plate and a fiberglass pad affixed to the bottom of the base plate. The combination of the slide plates and steel support the pipe while allowing it to move freely along the supporting base plate and structural steel due to the mechanics of the piping system or events such as thermal expansion.
These hold down pipe clamps were designed for pipe sizes 1 1/2″ to 6″ and the slide plates are designed to handle temperatures from -320 degrees F to 500 degrees F. The components were custom painted per the customer’s specifications. See the drawing below that shows the different types of base plates required for a variety of pipe size configurations. We can also custom design a hold down pipe clamp for your specific application.
We recently manufactured two different styles of pre-insulated pipe supports with Pyrogel-XTE insulation to be installed on high temperature culvert pipelines. The culvert measures 42″ and the process pipe measures 24″. Both styles are fabricated from carbon steel. The roller type shown below includes a three coat paint system to withstand a more humid environment.
These particular pipe supports, shown above and below, are designed to support loads ranging from 17,000 lbs up to 30,000 lbs and measure 18″ long.
Both of these pre-insulated pipe support designs will be installed within a culvert, as shown below (right), and help to minimize the amount of heat loss in the pipeline while allowing axial movement of the support due to thermal growth. The pipe supports shown above include heavy duty track roller bearings that are coated with high temperature grease. The design shown below incorporates slides fabricated from UHMW polyurethane. These custom designed features facilitate the installation of the process pipe in the culvert by allowing the pipeline to be smoothly and easily pulled through the culvert. The culvert can be up to 1/8th of a mile long in some cases.
Just wanted to touch base with you to let you know that we have recently expanded our engineering and design capabilities to include a wealth of value added services for your next project for a variety of industries including oil and gas, petrochemical, fertilizer, chemical, power plant and more.
In addition to pipe support 3D modeling and finite element analysis, we can now supply engineering assistance on your entire project, from start to finish. Do you need an analysis of high temperature pipelines in new or existing plants? Do you require detailed information on lines connected to steam boilers, thermic fluid boilers, turbines or pumps? Rilco offers a highly experienced and talented engineering team for your entire piping systems, including the pipes, hangers and supports.
If you have any problems that have surfaced in the pipelines of your current projects, we can also provide assistance with troubleshooting of the pipe supports and deformation of the pipes. Additionally, we can create and review P&IDs, perform CFD and surge analysis, prepare detailed feasibility reports, implement process safety audits, and much more. Do you have any engineering needs on your current or upcoming project?
Rilco Manufacturing recently fabricated carbon steel sway struts for a local propane dehydrogenation unit. The sway struts are Rilco Size 8, designed for a 120,000 lb. load. They will attach to existing structural steel and a double lug bracket that is welded to a large 112″ floating ring. The floating rings are supporting large axial loads and simultaneously restraining surge loading on a high temperature pipeline.
The sway struts are designed to work in conjunction with the floating rings to limit the axial movement on the pipeline. Pictured below are the floating rings installed on the 112″ pipeline within the propane plant. The double lug brackets are shown which will be the attachment point for the above sway struts when installed.
Sway struts are typically used to restrain movement of piping while allowing for movement in the other two directions. They are effective under either tensile or compressive force. The self-aligning bushings permit a plus or minus 5-degree misalignment or angular motion. The maintenance-free bushings are coated with dry lubricant to facilitate articulation. The complete assemblies are galvanized, to prevent corrosion in the field, prior to shipping to the customer.
Rilco Manufacturing recently manufactured several large E-Type RCR constant spring support assemblies for an above ground crude oil storage terminal. They will be utilized in a pipeline terminal with more than 18 storage tanks. See the constants pictured below with a selection of our stock variable spring cans shown behind them. The constants will be installed in the field with a threaded rod and stainless steel clamp attached to the pipeline.
The two interconnected opposing springs located within the RCR housing acting in conjunction with the main spring enable achievement of absolute load setting reliability. RCR constants transfer the load directly through the center of the body, eliminating the moment imposed on the supporting members.
These constants were manufactured with stainless steel pins, galvanized cases, custom powder coated components, special coating to reduce friction and wear in the field, and underwent precise adjustments to the load requirements for optimum operation in the oil storage terminal. They are designed for an operating load of 18,480 lbs and 5″ of downward travel.
Prior to shipment, all of the constants were tested for operational ability and proper setting in accordance with the customer specifications and Rilco’s quality control standards.
Are you planning to attend the upcoming Gastech Exhibition & Conference in Tokyo, Japan? We would be delighted if you would visit us at the venue, Makuhari Messe, in Chiba-city in Tokyo, Japan from April 4th to April 7th. We are eager to talk to you and show you samples of our unique CryoWrap™ pipe support as well as our polyurethane and FOAMGLAS® pre-insulated pipe supports. These particular supports carry the load of the pipe and save a great deal of time and money in construction costs as well as energy savings, thus reducing overall costs throughout their lifecycle.
The particular pipe supports shown below are Rilco CryoWrap™ pipe supports that are applicable for cryogenic environments down to -450 deg F (-268 deg C). They function as a resting, guided or anchor support and are used widely in the oil and gas processing industry, such as LNG, LPG, and ethylene plants.
You will find our display located at Booth 9325. If you are able to stop by our stand, we would be happy to personally answer any technical questions you may have regarding these or any of our Rilco pipe support products that we offer.
We recently manufactured several F-Type variable spring pipe supports for a hydrogen plant in Turkey. These variables included PTFE, 25% glass filled slide plates in the design, in order to allow for movement of the pipe on the load flange. This particular custom designed spring required machining of the load flange to ensure that the PTFE, 25% glass filled slide plates remain mechanically captured during operation.
The variable springs pictured are designed for various operating loads ranging from 2,338 lbs to 5,390 lbs. They will be utilized to support pipes with hydrogen and high quality export steam. This particular design, the F-type, is designed to support the piping from below. They are generally used to support pipe from the floor or where support from overhead is not practical.
Some of the standard design features for Rilco variable springs include:
• Load indicators are visible in the travel slots and the loading is easy to read
• All springs are protected from weather conditions & damage by the spring casing
• Closure plate operates as a centering unit & a guide sustaining spring alignment.
• Every size has reserve travel (over travel) at both higher and lower boundaries of the operating range of the spring
• Springs are calibrated for accurate loading
• Spring and casing are fabricated from steel making them compact and rugged
• Cold set at the factory to exacting customer requirements
• The spring coil is epoxy powder-coated to provide protection to the coil, while the unit is hot dipped galvanized per ASTM A153 protecting the unit from corrosive and climatic conditions
Should some detail of construction or piping arrangement make it necessary to deviate from our standard variable spring designs, we, through our superior design team and our state of the art manufacturing facilities, are equipped to furnish hangers and supports to meet your most stringent requirements. We are continually monitoring our projects and collaborating with engineers and architects in the preparation of specifications for variable spring requirements and the interpretation of applicable piping codes.
In addition to the F-type variable springs mentioned above, we also supplied several sway struts, pipe clamps, spring hangers and Rilco Cam Roller constants for this particular job in Turkey. Do you have any applications that could benefit from the use of variable spring supports on your upcoming projects? Please let me know how I can serve your needs.
Pre-Insulated pipe supports are an ideal solution and provide maximum efficiency on a pipeline when you are looking to isolate the pipe from the outside structure. They offer an immediate thermal break and eliminate “radiator fin” heat loss through the base. They also help to keep BTU’s in or out of the pipe depending on the temperature of the service.
When utilizing uninsulated pipe supports that weld directly to the pipe or clamp directly to the pipe, there is sometimes significant heat loss into the atmosphere that also affects the support directly and the surrounding area. This is shown in the photographs below with the snow melting around the supports and also reflected in the thermal analysis performed on the pipeline.
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Our research and development team performed a test on a pre-insulated pipe support, weld-on shoe, and clamp-on shoe in a shop environment at approximately 75-80 degrees F. The test was performed in a calm environment with no wind. Wind across a piping system, and especially the welded support, will significantly affect the heat loss and energy usage. The images below show the thermal loss across the various types of supports. The pre-insulated supports minimized the loss of BTU’s at the support thereby proving to be much more efficient.
On the pre-insulated support, the pipe is totally isolated by insulation from the outside of the support and the environment. The weld-on and clamp-on supports do not have any thermal break between the pipe and the outside of the support thereby acting as a radiator fin, proving to be very inefficient.
Installing weld-on supports proves to be costly with expensive labor rates to weld and time consuming welding and additional quality control time. It also requires extensive labor to trim insulation and jacket around the steel ribs. Another option besides pre-insulated pipe supports is to insulate entire sections of the pipeline prior to installation using the modular approach.
Benefits of Pre-Assembled Pipelines:
Additional benefits to pre-insulated pipe supports include the prevention of corrosion under insulation. Since the pre-insulated pipe supports totally isolate the pipe from the outside structure, CUI is greatly minimized. Pre-insulated pipe supports can also include a sealed vapor barrier system for cold applications to eliminate condensation on the pipe.
From all of us at Rilco Manufacturing, we would like to wish you a very prosperous and happy new year. I would like to thank you for your business in 2016 and I am looking forward to collaborating with you in 2017 to provide you with high quality pipe support solutions and excellent service!
Recently, we provided Foamglas® pipe supports to a local chemical plant. We offer Foamglas® pipe supports for hot, cold and dual-temperature applications.
Foamglas® Pipe Supports Being Prepared for Shipping
Some of the benefits of Foamglas® insulation include:
The range of temperatures that these supports can withstand is from -450 deg F to 900 deg F. Our dual-temperature supports are an ideal solution when you require an insulated pipe support to function at both high and low temperatures. These particular pipe supports are made primarily of either Foamglas® insulation or Pyrogel insulation. They are reinforced by structural insulating inserts that support the load on the pipe.
Ideal Applications for Foamglas® Pipe Supports:
Do you see a need for Foamglas® pipe supports on your upcoming projects? Please let me know how I can help you out with your pipe support and fabrication needs in 2017!
Rilco Manufacturing recently supplied a variety of high load bearing Rilco Cam Roller (RCR) constants to a local propane dehydrogenation plant. Several of our B-type constants were selected to compensate for the vertical movement of the piping system at a performance level previously unattainable using a standard or vertical type constant.
The operation of these RCR constants is based on the interaction of force between the main spring load and the forces provided by two interconnected springs. The opposing springs acting in conjunction with the main spring enables achievement of absolute load setting reliability.
Overall View of Multiple Cam Roller Constants in a Local Plant
Loads subjected to the main spring, which is connected through the load column, activates the opposing springs, thus activating a system of specially engineered cams, rollers and pins which in turn also exert force on the main spring. As loads are transported over the travel range of the piping, the forces on the main spring and opposing springs change based upon the angle created by the specific shape of the cams, and the design characteristics of the spring.
As loading is applied and the travel moves downward towards the apex of the cams, the opposing spring load is minimized in direct proportion to loading on the main spring. Upon reaching the apex, the opposing force is zero, as the main spring is carrying the load without assistance, traversing past the apex, in a downward motion, the direction of the compensating springs begin to reverse thereby reducing the load on the main spring as well. The constant support is achieved as a result of the alignment of these components so that any deviations in the load are matched exactly with the loading on the main spring.
Rilco Cam Roller Constants Supporting Rilco Fabricated Floating Rings in the Field
Advantages of Rilco Cam Roller Constants Over Lever Type
Do you have any requirements for our RCR constants or any other pipe supports or steel fabrication on your upcoming projects? Please let me know how I can serve your needs.
Looking for an ideal pre-insulated cold pipe support for utilization in your LNG plants or shipbuilding projects? Rilco Manufacturing provides a reduced cost pre-insulated pipe support, fabricated from Cryogel® Z insulation material, that can be easily transported without any damage to the components or installed location. It provides an extremely cost-effective solution for the insulation process on a pipeline and facilitates the coordination of the construction schedule.
The Rilco CryoWrap™ pipe support proves to be a supreme support choice for ships particularly because the insulation is hydrophobic which prevents any moisture droplets from penetrating the insulation. The vapor stops that are incorporated into the support design at each end also restrict moisture intrusion. See a custom CryoWrap support below with slide plates incorporated into the design for easy movement of components that are in contact with the pipe support on the line.
CryoWrap™ pipe supports also offer unparalleled resistance to flame spread with minimal smoke emission and no toxic effects. Each product protects both piping and equipment longer thereby extending the reaction time needed to respond to serious events. The lighter weight and smaller circumference requirements of Cryogel® Z insulation means reduced overall loading of pipe and equipment support systems. The superior resistance to mechanical abuse attests to the product’s durability, the smaller circumference eases installation and reduces labor costs.
CryoWrap™ pipe shoes are capable of resisting high impact loads from compression forces of hundreds of psi without sustaining damage or compromising performance. Unlike pipe supports utilizing rigid insulation which is friable and prone to cracking under loading, pipe supports using CryoWrap™ will not allow thermal leaks or moisture intrusion.
CryoWrap™ pre-insulated pipe supports are also an ideal solution for ships since they are environmentally friendly. They are capable of adherence to the most exacting environmental regulations. Because the insulating aerogels are basically silica (sand) and contain no respirable fibers, CFC, HCFC and do not require blowing agents, they pose no chemical threat to the environment.
Rilco Manufacturing has a new manufacturing facility, on Tanner Road in Houston, with plenty of capacity to fabricate these particular supports. With over 400,000 square feet of production space and a staff of experienced professionals with over 100 years of combined experience in pipe support design, we are fully capable of handling your upcoming needs.
Do you have an immediate requirement for cryogenic pipe shoes due to a quick new construction, repair or plant shut-down for maintenance? We can offer you quick-turn high quality CryoWrap™ pipe shoes as the ultimate solution for your cryogenic applications. Please let us know how we can help you today.
Do you have an immediate need for steel fabrication for a repair or replacement? Are you looking for a pipe support solution to fix a current ongoing pipeline issue? Rilco is now offering quick-turn services for steel fabrication including, but not limited to, structural supports, instrument stands, uninsulated pipe shoes, pipe stands and embeds. Whether you need something within 2-3 days or 2-3 weeks, Rilco is currently fully capable of providing all of your quick turn-around steel fabrication needs.
With over 400,000 square feet of production space and a staff of experienced professionals with over 100 years of combined experience in pipe support design, we have the expertise to carry out your last minute pipe support needs with the highest quality of service.
Our in-house supply of a variety of metals, miscellaneous hardware, newly added capacity and more provide us with the ability to now offer you a significantly reduced manufacturing lead time.
Do you have a quick-turn need that we could help supply you today?
Rilco Manufacturing designed and fabricated custom big ton springs for a refinery in California. These springs were fabricated from carbon steel and included four powder coated spring coils and four hydraulic cylinders. The cylinders connected to a common hydraulic manifold by tubing and fittings. See close-up of the internal components below.
The big ton springs were designed for a cold load of 45,900 lb., a hot load of 43,000 lb., and a retracted load of 61,900 lb. Additionally, they were designed with a spring rate of 16,000 lb./in. and an upward travel of 0.2 inches. The big ton springs measure 20″ high x 18″ wide x 52″ long.
They were fabricated to support large pressure vessels in the refinery. When the hydraulic cylinders are activated, the spring coils self-retract down to facilitate the movement of the vessel for maintenance.
The completed big ton springs, shown above, underwent load testing prior to shipping to ensure quality control.
Do you have a need for big ton springs or any other pipe supports on your upcoming project?
Rilco Manufacturing offers a wide variety of fabrication from a vast assortment of materials. From structural supports to un-insulated pipe clamps to pipe stands and pipe cradles, we can provide you with fabricated steel for all of your pipe support needs. Rilco complies with most all industry standards including ASTM, ASME, AWS and more.
Carbon steel pipe cradles below, being prepared for inspection and shipment.
Rilco performs an assortment of heat treat processes to our metals throughout the fabrication process. Stress relief (post-weld, post-form), hardening and annealing processes are utilized accordingly to meet industry standards and ensure the highest level of product quality. Proper forming practices, annealing and post-form stress relief help ensure the cold work stresses and hydrogen embrittlement do not compromise the integrity of the pipe supports.
Rilco offers a variety of testing including dye-pen inspection, radiograph, ultrasonic, PMI, mag particle inspection, and hardness testing to ensure quality prior to shipping your pipe supports.
Do you have a need for fabricated steel supports on your upcoming project?
Rilco Manufacturing is now offering field services to our valued customers around the world. Do you have a scheduled shut-down coming up? Can we assist you with any installation, repairs or maintenance within your facility? We have a team of factory authorized field service representatives that are available to travel both within the United States and internationally to fulfil your needs.
We have extensive experience helping our clients evaluate their pipe support installations/applications and providing high quality pipe support solutions that are guaranteed to perform under the most severe field conditions. Whether it’s an entire survey of your pipe support system, assistance with installing your supports, pipe support testing or training on pipe support installation and maintenance, you can count on our team to provide you with superior quality field services.
Do you have a need for field services at one of your company’s plants or refineries?
Rilco Manufacturing just finished shipping our largest ever quad unit Rilco Cam Roller Constant (RCR)designed for a 55,000 lb. load and 21″ of upward travel. It is designed for a high load, long travel application in a local propane dehydrogenation plant. This B-type constant consists of a combination of 4 single unit RCR constants to accommodate the heavy load. The overall weight of the RCR constant is 11,000 lbs.
Type B is defined by a single lug top mount which is bolted to the RCR assembly. This type of arrangement is typically used in situations which require the constant assembly to be close mounted to supporting structure, or in retro-fit applications. The top single lug typically works in conjunction with a clevis or a welded beam attachment. The lower attachment point consists of a swivel coupling with right hand threads for the hanger rod connection for single unit assemblies. The lower connection of these particular units is a custom double lug C-type to accommodate the single lug connection to the pipe when installed in the field.
Multiple unit assemblies, like the quad unit we’ve discussed, typically use a single common lug for both the top and bottom connections. They can use the same connection arrangement on the top as the single unit assemblies, but require a clevis or a double lug arrangement for the lower connection. The quad unit RCR constants are capable of up to 30″ of travel or up to a 120,000 lb. load.
Prior to shipping this unit, the cam roller constant underwent load testing for quality assurance as shown below in our custom designed testing machine alongside a single unit RCR constant.
Do you have any upcoming jobs that may require Rilco Cam Roller constants?
Rilco Manufacturing recently fabricated dual temperature pre-insulated pipe shoes for a local ethylene plant. The pipe supports will be used primarily for a cryogenic pipe line. However, at times certain phases of the chemical process will include high temperature fluid flowing through the pipe. In order to eliminate the risk of deterioration of the polyurethane foam, a layer of Pyrogel® XTE insulation was included in the design, thus creating a dual temperature pipe shoe that supports both the high temperature and cryogenic processes.
The entire job included a wide range of diameters, with some designs featuring two base plates that will restrain the piping at two different positions, like the ones shown below.
Rilco was among the companies that pioneered the polyurethane pipe supports which are now used industry-wide. The insulation can be molded to the thickness and layering of process line insulation to ensure proper field fit per ASTM C585.
Traditional polyurethane supports are applicable in low temperature environments down to -350 degrees F. Condensation is eliminated along with the associated field corrosion problems. Temperature fluctuation at the support point of process fluids is eliminated, and designs can be customized for specialized client specifications or loading requirements as the dual temperature ones discussed above.
Do you have any upcoming jobs that may require custom designed pipe supports?
I’d like to share with you that we have partnered with Matec® Group, a high quality expansion joint supplier in Italy, to provide you with an extensive line of expansion joints including, but not limited to, metallic, fabric, gimbal and rubber expansion joints.
Please see the photo below that highlights some of Matec’s past projects.
Through our partnership with Matec, we can now offer you:
We recently fabricated galvanized carbon steel pre-insulated resting pipe supports with Foamglas® insulation. Foamglas ® provides constant insulating efficiency and strength. It can be used for both hot and cold applications and the minimum temperature being -20 degrees Fahrenheit. The insulation thickness we provide ranges from 0.5 inches to 10 inches, and we offer pipe sizes from 0.5″ to 120″ in diameter.
Do you have any upcoming jobs that may require expansion joints or pre-insulated pipe supports?
I’m writing to touch base with you and let you know that besides providing a wide variety of pipe supports and insulated supports, we also fabricate a large selection of structural steel supports. The angles and beams shown below are part of a large job that will be shipped to a local gas liquifaction plant. The job also included other fabricated steel including spring guides, axial stops and u-shaped supports as well as an assortment of pipe supports.
We can handle almost all types of steel fabrication. Some of our most commonly fabricated items are:
Below are some carbon steel pipe stands, prior to being painted, that we fabricated for an LNG plant in Texas. The pipe stands range in length up to 38 feet long.
Below are a few applications and combinations of the structural steel we provide:
Do you have any upcoming jobs that may require pipe supports or steel fabrication?
From all of us at Rilco Manufacturing, we would like to wish you a very prosperous and happy New Year. I am looking forward to partnering with you in 2016 to provide you with superior quality pipe supports and excellent service. Please let me know how I can serve your 2016 project needs.
Rilco Manufacturing recently fabricated the below custom designed sway braces for a refinery in Washington state in the U.S. The sway braces measure 46 1/8″ long with an O.D. of 8″. They are designed to support loads ranging from 450 lbs to 2700 lbs. The spring rate for these sway braces is 450 lbs/inch and they are designed for a travel of 5″. They were custom designed with a larger can to accommodate a larger spring coil for the 5″ of travel.
Sway braces are used for a variety of applications including controlling vibration, absorbing shock, leading, guiding or restraining the movement of pipe resulting from thermal expansion and bracing a pipe line against sway.
Sway Brace Features:
Do you have any upcoming projects that may require sway braces?
Rilco Manufacturing would like to wish all of our customers and partners throughout the world a Merry Christmas and wonderful holiday season. This past year has brought us several exciting new challenges. Our migration to a brand new facility on Tanner Road has provided us with a great deal of additional shop space to service your pipe support and fabrication needs.
We are currently fabricating the largest Rilco Cam Roller Constants that we have ever made. Below is an image of our quadruple unit RCR constants being load tested.
However, larger constants are planned for 2016, so you can look forward to hearing about those in an upcoming newsletter!
We wish you and your families safe and special times during this holiday season and may you find health, happiness and peace. We hope to serve your pipe support needs in 2016.
Do you have any upcoming jobs in the new year that may require pipe supports or steel fabrication?
Rilco Manufacturing provided several hydraulic snubbers with external pressurized reservoirs for a plant in Louisiana. They measure 42″ bracket to bracket, with a cylinder size of 5″ and a stroke of 5″. The maximum load that these snubbers can withstand is 45,400 lbs. Prior to being shipped, these hydraulic snubbers underwent various quality tests including lock-up velocity testing and bleed rate testing.
Snubbers are designed to protect pipeline components from surplus shock caused by various disturbances or forces, such as an earthquake. During normal conditions the snubber will allow for movement in tension and compression, but when a disturbance occurs the snubber will act as a restraint device and absorb the energy or shock.
Rilco also provides snubbers with internal pressurized reservoirs such as the ones shown below. These hydraulic snubber assemblies include a double bolt carbon steel pipe clamp.
Do you have any upcoming projects that require hydraulic snubbers for shock control?
Rilco Manufacturing is currently shipping several Cryowrap™ pipe shoes to an LNG plant in Thailand from our new Tanner facility in Houston, TX. The CryoWrap™ supports are manufactured with insulation that matches the diameters of the Aspen Aerogels Cryogel Z™ insulation diameters enabling the system to be designed with the piping nested closer together as well as allowing for easy/seamless transitions from the support to the line insulation.
The insulation material itself is hydrophobic preventing any moisture droplets from penetrating the insulation; furthermore, our supports are built with vapor stops at each end restricting moisture intrusion. These two components combined, virtually eliminate the threat of CUI (Corrosion Under Insulation) at the pipe support.
The design of our system enables the “modularization” of the pipe and the option to pre-install all components either off site, or at a safe location on site. The complete system can then be transported without damage to any components to the jetty or pipeline location. This has proven to be an extremely cost-effective method of construction and facilitates the coordination of the construction schedule.
Additionally, Rilco has performed various cryogenic tests on the CryoWrap™ pipe supports which has enabled us to refine the design and ultimately develop a pipe support that out performs all cryogenic supports currently on the market. The cryogenic tests have involved 36 inch pipe with 120 mm of the Cryogel Z™ insulation with our proprietary rigidizing agents chilled to pipe temperature of (-)165 °C.
Through the measurement of heat gain through the insulation, deflection of the insulation at design load, and testing the axial force/clamping force, these tests have demonstrated the ability of a pipe support system constructed primarily of Cryogel Z™ to perform both structurally and thermally. All temperatures, forces, and displacements are monitored and recorded digitally throughout the entirety of our cryogenic tests.
The graphic below illustrates the difference in diameters between Cryogel Z™, Cellular Glass and PIR, while all three designs still meet the same condensation control criteria.
Do you have any upcoming projects that could benefit from the use of Cryowrap™ pipe supports?
Rilco Manufacturing custom fabricated these f-type variable springs for a local ethylene cracker unit. They are designed for an operating load of 18,000 lb. with an upward travel of 1/16″. They are fabricated from carbon steel and hot-dipped galvanized. The variables include a PTFE, 25% glass filled slide plate (not pictured) welded on the top carbon steel flange, and a polished stainless steel plate is included to be welded to the bottom surface of the load support for movement of the pipeline.
Variable springs are used to support piping which is subject to thermal expansion and other factors which cause the pipe support point to move. They are called “variable” because the force exerted by the “spring” varies through their range of travel. As the supported pipe moves upward, the force exerted by the “spring” decreases. Conversely, during downward travel, the force of the “spring” increases.
Variables support piping where thermal movements cause the system position and dimensions to change. They’re also commonly used where the transfer of an uncontrolled load can cause damage to the equipment.
A “variable” spring may not necessarily be recommended in all the above applications, however. As an example, when the variability surpasses 25%, our constant spring support should be used.
Some of the optional design features you can include when ordering variables:
Below are various types of variable springs that Rilco offers. The type of “variable spring“ hanger to be utilized depends upon several variables. Those include the physical characteristics of the hanger attachment, whether it will be supported above or below the spring and the potential of interference from other components.
Do you have any upcoming projects that may require the need for variable spring supports?
Rilco Manufacturing recently tested one of our 42″ cryogenic pre-insulated pipe supports in our Research & Development lab. The purpose of the test was to evaluate the physical performance of a resting pipe support under its design load.
The equipment used for this test included a structural test frame, a 50 ton Enerpac single acting hydraulic cylinder and hand pump (to apply the vertical load), a 100k compression load cell (to record the load), and linear displacement transducers to measure the vertical consolidation during loading, placed on each side of the support to confirm uniform deflection.
The insulation component consisted of Cryogel reinforced with a rigidizing agent. The rigidized agent’s purpose was to provide the structural support from the pipe to the steel cradle while also protecting the thermal resistance from the design temperatures.
The design load was applied manually to the support using the hand pump at a rate of approximately 200 kN/min. Once the load was reached, it was maintained for 5 mins. The test unit passed upon the acceptance criteria, ensuring the structural integrity of the support. (See image below of the test in progress.).
Rilco performs rigorous in-house testing of all newly engineered products. Typically for the testing of insulation materials, such as Polyurethane and Permali, we utilize our Baldwin BTE 400 that has a load cell of 400,000 lbs. testing capability in both the tension and compression aspects. The BTE 400 is also controlled by the latest Instron fully digitized servo controller that is capable of performing and collecting data on every possible test configuration.
Some of the research experiments we conduct at our facility include:
Physical Load Testing
Low Temperature Testing of Polyurethane and Cryogel® Z Insulated Pipe Supports
High Temperature Testing of Calcium Silicate and Pyrogel® XT-E Insulated Pipe Supports
Low Temperature Coil Spring Cyclic Testing
Belleville Washer Fatigue Testing (See image below.)
The engineering and R&D departments work closely together to ensure all products meet or exceed industry standards before a Rilco product is launched.
Do you have any upcoming projects with custom or specialty products that could utilize Rilco’s innovative pipe supports?
Rilco Manufacturing is presently fabricating and testing several Rilco Cam Roller (RCR) constants between our two Houston facilities. The RCR constants have been designed to compensate for the vertical movement of a piping system at a performance level previously unattainable using a standard horizontal or vertical type constant.
Site installation is also enhanced via the use of a centered, single point connection. RCR constants transfer the load directly through the center of the body, eliminating the moment imposed on the supporting member.
The load capacity that is offered for this particular type of constant ranges between 20 lbs and 120,000 lbs. The travel range is from 1″ to 30″. The RCR constants are field adjustable up to 50% of the load and include a carbon steel housing.
The RCR constant support incorporates all of the necessary elements to create a near perfect constant:
Every RCR is tested for operational ability in accordance with client specifications & quality control standards prior to being shipped. (see photo below)
Last week we visited Calgary, Alberta, Canada for a lunch & learn networking event with one of our insulation partners! Guests got to see a live demonstration of a pre-insulated system with Rilco pipe supports installed and learned about the unique thermo-mechanical properties of Pyrogel® insulation.
Would you like us to visit your company for a Lunch & Learn Demo opportunity? Just reply to this e-mail with a date and time you would like to set it up!
Also, do you have any upcoming projects that could benefit from the use of Rilco’s cam roller constants?
Rilco Manufacturing is currently fabricating several PyroWrap™ pipe supports in our new Tanner Road facility in Houston. The Rilco PyroWrap™ pipe supports outperform all other pre-insulated hot service supports providing numerous commercial and technical benefits for your project needs.
The PyroWrap™ supports are manufactured with the same diameters as the Pyrogel XTE™ insulation diameters allowing for seamless transitions from the supports to the line insulation, as well as, allowing for the piping to be nested closer together in the design of the system.
The Aspen Aerogels Pyrogel XTE™ insulation material is hydrophobic meaning it will prevent any moisture from penetrating the insulation itself; however, the water vapor is still able to escape through the insulation. This feature improves the insulation efficiency and essentially eliminates the potential for CUI (Corrosion Under Insulation) at the pipe support.
The PyroWrap™ system design permits for the “modularization” of the pipe which then gives the option for the support systems and insulation to be pre-installed off-site, or on-site at a safe location. If pre-installed, the complete system can be transported without damage to any components. This method has been proven to be an extremely cost-effective method for construction.
The graphic below illustrates the difference in diameters between Pyrogel XTE™, Calcium Silicate, Mineral Wool and Expanded Perlite, while all four designs provide the same level of thermal protection.
This week Rilco is at the International District Energy Association (IDEA) annual conference and trade show in Boston, Massachusetts. If you are in the area, come check us out at Booth 7A!
Do you have any upcoming projects that could benefit from the use of PyroWrap™ pipe supports?
Rilco Manufacturing Company, Inc. is currently fabricating over 50 floating rings for a local propane dehydrogenation plant. The floating rings range in diameter from 48″ to 112″. They will be utilized to support large axial loads and simultaneously restrain surge loading on a high temperature pipeline. They are fabricated from 316H stainless steel plates that range in thickness from 1/2″ to 2″. This particular material was chosen to withstand the heat of the pipes (up to 1500 deg F) passing through the center of the rings.
The floating rings will be installed in the field both horizontally and vertically. The horizontal rings include four arms which will have struts attached to them via the double lug brackets at the end of each arm. The vertical rings include two arms which will have Rilco cam roller constants attached to lugs on each end of the arms.
All of the welds performed on these floating rings are full penetration welds. Prior to shipping, NDE testing has been performed on the supports including PMI, dye-penetrant testing and ultrasonic testing.
Do you have any upcoming projects that require custom fabricated pipe supports?
Rilco Manufacturing Company, Inc. provides a wide variety of pipe supports between its two current facilities with now over 200,000 square feet of space to design and manufacture high quality supports for your needs.
Our facilities are divided into four functional areas including an insulation shop for our pre-insulated pipe shoes, a steel fabrication shop for all of our miscellaneous fabricated components, a variable and constant spring shop, and an assembly floor to ensure that our customers’ orders are properly assembled, inspected and tested prior to shipping.
We utilize an assortment of machines including press brakes, plate rolls, plate shears, saws, iron workers, plasma/oxy fuel burners and a water jet machine. We can provide pipe shoes and supports with standard diameters ranging from 1/2” to 120” in diameter as well as custom made sizes with materials such as carbon steel, stainless steel, chrome alloys, and inconel for your particular application. We also offer a variety of finishes including shop prime, powder coating, hot dipped galvanizing and a 3-part epoxy paint system.
Rilco is CWB certified for welding and also ISO 9001 certified for the design and manufacture of insulated pipe supports, steel fabrication and spring hangers. We recently fabricated these calcium silicate high temperature pre-insulated pipe shoes for a silicone manufacturing facility. They ranged in diameter from 2” to 16”.
We recently fabricated these calcium silicate high temperature pre-insulated pipe shoes (pictured) for a silicone manufacturing facility. They ranged in diameter from 2” to 16”.
Do you have any upcoming projects that require pipe supports?
Over the course of the last year our new facility on 12700 Tanner Road has been under construction. The finishing touches have been completed in the last month and it is time to start moving. Although we will be keeping our shop on Brittmoore Park Drive for the extra space and capacity, our headquarters will now be at the Tanner location.
Production Capacity
With the additional 120,000 square feet and the strategic setup of production lines, new equipment, additional space, and a revitalized focus on efficient manufacturing we will essentially double our current production capacity. We are excited for the projects we have secured to fill the new shop this year and are looking forward to many more to come!
Can we provide you a quote on your upcoming pipe support needs?
Next month Rilco will be exhibiting at HRSG in Orlando, FL and at NACE Corrosion in Dallas, TX. HRSG will be held on March 9th-11th and NACE will be held the following week on March 16th-19th. If you are in either area and are interested in stopping by our booth please let us know!
HRSG Conference 2015
The HRSG Conference and expo is the premier gathering place for the combined-cycle/cogeneration operator industry. This conference will host over 500 attendees and will focus on the range of challenges engineering faces in these combined-cycle/cogeneration plants. Rilco specializes in the customization of our pipe supports and other product offerings, so that we can meet the needs of almost any project type.
NACE Corrosion Exhibit 2015
Nace is the world’s largest conference and expo focused on the prevention and mitigation of corrosion. More than 7,000 professionals and 450 companies will be attending in Dallas, TX and Rilco will be one of them. We will be showcasing how Rilco’s CryoWrap and PyroWrap pre-insulated pipe support systems can help prevent and significantly reduce the major costs associated with CUI, or corossion under insulation.
Rilco Manufacturing Opens New Headquarters
Last year we announced that we would be expanding our facilities. It has been quite a journey planning and constructing the new headquarters, but it is now 2015 and the building is up and (almost) fully functional. Our entire staff is excited and anxious to move just a mile and a half down the road to the newest Rilco location on Tanner Road.
With this new additional manufacturing and office space we hope to more than double our current productivity which will prime us to make deliveries and meet our clients’ expectations better than ever for the coming year!
As a way to honor those that have contributed to the success and growth of our company, late last year we held a handprint ceremony after the concrete was poured and welcomed any of our employees and their young ones to come leave a personalized mark in front of the building. Everyone enjoyed getting their hands a little bit dirty and making an imprint that will be sure to last a lifetime.
Heat Loss Evaluation
Rilco Pre-Insulated Supports vs Weld-On Supports
With infrared photography, the research and development team at Rilco has analyzed the heat loss of our pre-insulated supports compared to that of a weld-on support for a 24” steam line in order to determine which is more effective in regard to energy conservation.
When the supports were tested, the imaging revealed that the pipe temperature at the weld-on support point had a very large reduction in process temperature due to its various thermal inefficiencies. These inefficiencies in real-life applications result in significant amounts of wasted energy over the life of the plant, lower quality steam, and process problems due to cold spots.
With these findings in mind, we then calculated the potential total energy savings for the lifetime of a plant. It totaled up to 315,360,000 kW conserved over a period of 30 years. Therefore, Rilco pre-insulated pipe supports save a vast amount of energy resulting in largely reduced energy costs.
The ” Rilco Royalty” Team Competes in the Gritty Goddess 5K
On October 11th a group of Rilco employees teamed up for a mud run called the Gritty Goddess in Galveston, TX. As an effort to support our local community, Rilco sponsored the team in order to support the two great causes benefiting from the event. Proceeds from the race were donated to Girls on the Run and The Rainbow Connection.
Girls on the Run is an organization dedicated to a transformational physical activity-based positive youth development program for girls ages seven to 14 years old. The program prepares girls physically and mentally to complete a 5K running event. The goal of the organization is to promote young girls’ self-esteem and confidence while encouraging a wholesome, healthy lifestyle.
The Rainbow Connection is a program that enables children with blood disorders or cancer to attend summer camp along with their brothers and sisters. Their mission is to help young people confronting these illnesses re-discover that they are normal kids too and deserve the opportunity to attend summer camp regardless of their family’s financial situation.
The Rilco Website has been Re-Modeled
This year we have initiated a shift in our business practices aimed at updating our processes, product designs, calculations and product catalogs, as well as updating our online presence. We have entered the world of social media and completely re-designed our website. The hope with the new design of the website is to improve the layout, update the content, and provide an enjoyable and informative experience for our clients and anyone interested in what Rilco Manufacturing has to offer.
We Would Love Your Feedback!
We are still in the process of refining and adding updated content and we would love to hear what you think of the new site and its functionality so far. We want our website to accommodate the needs of our clients and would truly appreciate your feedback!
Pipeline Construction
Brief History of the Industry in the U.S.
In 1859 the first commercial oil well was built in Titusville, Pennsylvania. Within two decades 80% of the world’s petroleum consumption was supplied by Pennsylvania oil fields. The first “barrels” of oil were transported in whiskey barrels by teamsters on horse-drawn carriages. This method was extremely expensive and inefficient which ultimately led to the construction of the first wooden pipeline. This pipeline was built in 1862 and was approximately 9 miles in length. Most of the pipelines and their accompanying pipe supports were constructed of wood in the early days of American history. These wooden supports acted as poor insulators for temperature-sensitive liquids. In the 1970’s Rilco played a major role alongside Dow Chemical in pioneering a sturdier, more reliable pipe support that utilized polyurethane foam as the insulation, ultimately transforming the industry.
Remaining at the Forefront of Technology
Rilco remains at the forefront of pipe support technology as we experiment with new designs and insulation materials. In the past year we have conducted several major research & development tests for our PyroWrap and CryoWrap pipe support systems. These tests have indicated potential for exponential energy and cost savings in hot temperature and cryogenic pipeline applications.
Six Months Down, Six Months to Go
Last October we announced in our newsletter that we would be expanding our manufacturing space by 120,000 square feet. Planning started and construction began in January. The new facility is expected to be completed by December of this year. The added space should almost double our production capacity. We are ramping up to take on the new workload made possible by the additional space, and preparing to further improve the company to ensure we function as efficiently as possible.
Progress Pictures:
Product Highlight: Constant Spring Hangers & Supports
Use: To support piping where the loading conditions cause too great a variability or too high of a loading condition for a variable spring support
Design: The geometric design ensures a constant amount of force exerted throughout the entire range of travel
Specifications: All of the Rilco constant support units are designed to meet the requirements of the ASME Code for Pressure Piping, ASME B31.1, B31.3, and MSS SP-58
Rilco is able to provide almost any type of steel fabrication — from un-insulated pipe shoes, pipe anchors and hold down clamps, to structural supports. This is possible because we utilize four different steel cutting systems that each provides certain benefits for various situations. By having several of each type of cutting system available at our facilities we are better able to meet our clients’ steel fabrication needs.
Plasma Cutting System
This machine is the lowest in purchase price and also maintains the lowest operating cost than alternatives. It has the fastest production rate (anywhere between 60-220 ipm), but the lowest cut edge quality and lowest cut part precision. However, to ensure top-quality products from Rilco, we use the highest quality plasma cutting machines available that utilize the latest technologies and are engineered for high torque and high resolution.
Waterjet Cutting System
The waterjet system is mid-range in regard to purchase cost, but has the highest operating cost compared to alternatives. Waterjets have the slowest production rate (anywhere from less than 1 to 15ipm), but maintain the highest cut edge quality, as well as the best cut part precision with no heat distortion. It also is the most flexible when it comes to the materials it is capable of cutting.
Laser Cutting System
Compared to the Plasma and Waterjet cutting system the laser cutting system comes in at the highest purchase price and mid-range operating cost. The laser system produces at a slower rate than the plasma (between 20 to 70ipm), but is a close second when it comes to its cut edge quality as well as the cut part precision. There is a small chance the laser can cause heat distortion and is strictly limited to metalics, some plastics and fiberglass, and some fabric.
Oxy-Fuel Cutting System
This cutting process rapidly oxidizes the steel in an exothermic reaction and is widely used for cutting steel of all shapes and sizes.
Oxy-fuel cutting is done in three steps:
(1) Preheat – steel is heated to kindling temperature (1800°F) at which it readily reacts with oxygen
(2) Piercing – once the steel is at temperature a jet of pure oxygen (cutting oxygen) is used to pierce through the plate of steel
(3) Cutting – when the cutting oxygen finally reaches through the thickness of the plate, the torch will move at a constant speed, ultimately forming the necessary cut Low carbon steel and some low alloys can be cut with this process since they contain oxides with a lower melting point than the base metal. Metals that form an oxide with a higher melting temperature than the original metal being cut cannot utilize this process.
Rilco performs thorough in-house testing of all newly engineered products as well as product components in order to ensure their safety and reliability. Our R&D team is the first to perform physical testing on Belleville washers – a crucial component in the Rilco CryoWrap™ and PyroWrap™ Pipe Support Systems.
Belleville Washer Test: Purpose & Procedures
The purpose of conducting the test was to evaluate the physical performance of Belleville washers after being cycled 10,000 times.
The general procedures for the test are as follows:
1. Load washer stack to the flat load 3 times; record load and deflection measurements using our washer design verification equipment
2. Cycle the same stack for 10,000 cycles to the designated cycle stack movement heights using the washer cyclic test equipment
3. Repeat step (1) with the same washer stack to verify load and deflection
Why the Belleville Washer Testing is Necessary:
Washers must maintain a high level of repeatability with respect to both washer deflection and pre-load in order for the Rilco CryoWrap™ and PyroWrap™ pipe supports to function properly throughout the lifespan of a facility.
Test Setup:
Belleville Washer Stack at the Bottom of the Cycle Stroke:
Belleville Washer Stack at the Top of the Cycle Stroke:
Deflection and Load Test Conclusions:
The testing showed a slight degradation in the pre-load forces, however the standard clamping force calculation, as performed by Rilco, for each support configuration allows a degradation many times the excess of what the testing yielded before the performance of the support would be negatively impacted.
Overall, the test was successful in showing that the Belleville washers used for Rilco pipe supports will maintain the required clamping force, so that the mechanical performance of the support itself will be properly reinforced.
The full test report compiled by Russell Mertens, one of our experienced engineering professionals, is available upon request.
Rilco has expanded its product portfolio and capabilities over the decades by increasing floor space, adding equipment, and remaining committed to meeting all of our customers’ needs. Rilco has implemented two types of manufacturing strategies, the “job shop” and the “flow shop”. With the addition of another 100,000 square feet of manufacturing space Rilco is further expanding our “Lean Manufacturing” and “Six Sigma” management strategies.
From “Job Shop” to “Flow Shop”
The first method of manufacturing that was initiated at Rilco was the “Job Shop” strategy. This process is characterized by the production of a variety of small to medium volume products and services which are labor intensive, process oriented, and offer intermittent workflow. The job shop strategy allows for a vast amount of customization for each project or client. This is a major reason why Rilco is capable of producing almost all types of pipe supports. This method has proven to be crucial in Rilco’s ability to compete on quality, speed of product delivery, customization, as well as new product introductions. As the volume of demand increased over the years Rilco added extra manufacturing capabilities that have been structured as a “flow shop”. It is typical for most manufacturing firms to begin as a “job shop” and develop into other strategies of manufacturing such as the “Flow Shop”.
The “Flow Shop” is configured to produce a high volume of products which are defined by streamlined workflow, dedicated equipment, and product oriented labor for specific projects. As demand grew for Rilco products over the years we developed a hybrid strategy that included both the Job Shop process which allows for customization and the Flow Shop process that utilizes fast, customized production machinery which aid in mass production.
Further Incorporation of a Lean Manufacturing Strategy
Lean Manufacturing was first derived in the Toyota Production System. This system was renowned for its focus on the reduction of waste throughout the production process which ultimately led to an improvement in overall customer value.
As capacity has been stretched with high volumes of standardized products along with our highly customized product lines moving through our shops, management has studied the current state and the potential options for evolving our manufacturing processes to best suite our company growth. So, with our facilities expanding another 100K square feet in the next year we have begun to implement a lean manufacturing system that will further streamline our production facilities.
Rilco, as a whole, is dedicated to the successful implementation of the lean system. All of our department managers have been trained and certified in both Lean Manufacturing and Six Sigma Management. We are all excited for the improvements to come as we aim to reduce and eliminate any of our wasteful practices and strive to reach 100% on-time deliveries for every project without sacrificing the quality of our products.
This month Rilco Manufacturing is participating in the NACE Corrosion Exhibition in San Antonio, Texas. We are highlighting our latest innovation in pipe supports, as well as our various pipe support products.
In honor of the tradeshow our March Newsletter features the topic of Corrosion Under Insulation.
What is CUI?
CUI, or corrosion under insulation, is a type of corrosion that is localized at the interface of a metal surface and the insulation utilized for that surface.
Why is it Significant?
Exxon Mobil Chemical conducted a study that indicated that in the refining and chemical industries the highest occurrences of leaks were due to CUI rather than process corrosion. The study also revealed that between 40% and 60% of piping maintenance costs stem from CUI. Essentially, this means that enormous costs are allocated toward repairing major equipment outages, unexpected maintenance costs, and excess unplanned downtime. CUI is one of the costliest problems facing industries such as Oil & Gas and petrochemical.
What are the Causes?
CUI is caused by various factors that are particularly common in the pipeline construction industry. Water, Oxygen, and warm temperatures combined with a piping surface covered by insulation that prevents evaporation and enables the buildup of moisture will quickly lead to CUI. Furthermore, traditional thermal insulation materials such as, calcium silicate, contain chlorides. If exposed to moisture, the chlorides could be released into a moisture layer on the pipe’s surface and result in stress corrosion cracking.
What are the Methods of Detecting CUI?
Detecting CUI can be an immense challenge considering that the corrosion is hidden beneath the piping insulation. Inspections for CUI are also not typically conducted regularly enough due to the high cost of removing the insulation, inspecting, and then re-insulating. There are various other detection methods such as conventional radiography, pulsed eddy current, etc. but they all pose similar high cost re-insulation issues.
If CUI has been a persistent problem with your projects contact a Rilco representative who can inform you on the ways in which our latest technology in pipe supports will virtually eliminate the possibility of CUI along with the significant costs associated with it.
The Rilco Manufacturing Company Research and Development team performed a final load and temperature test of the latest innovation in cryogenic pipe supports. With an audience of various clients ranging from EPC’s to Oil & Gas companies the in-house testing of the Rilco CryoWrap™ pipe support proved this new product to be the latest and greatest in cryogenics.
The Cryogenic test involved a 36” pipe and utilized 120mm of Cryogel™ Insulation and Rilco’s proprietary “rigidizing” agents chilled to a pipe temperature of -165 ˚C. This test demonstrated the ability of the Rilco CryoWrap™ to perform both structurally and thermally by measuring the heat gain through insulation, deflection of the insulation at design load, and the axial force/clamping force withstood by the support system.
CryoWrap™ pipe supports have the potential to shift the entire cryogenic support market. It permits for seamless transitions from the supports to the line insulation, the system is hydrophobic – eliminating the potential for CUI, can be pre-installed creating labor cost savings, and the effectiveness of the insulation creates exponential long-term energy cost savings.
To request a cryogenic test report from Rilco Manufacturing Co. contact marketing@rilco.com and to learn more about Rilco’s various product portfolio visit our Products page.
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