R

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

PROJECT REPORT
On

SPRING SUPPORTS

Reliance Industries Limited

(JAMNAGAR EXPORT REFINERY PROJECT)

CLEAN FUELS COMPLEX

Submitted by,

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

ANIRBAN
SAHA
EC NO:
16242334

CERTIFICATE

This is to certify that Mr. Anirban Saha, EC No 16242334 has carried out the project on SPRING
SUPPORTS in FLUIDIZED CATALYTIC CRACKER UNIT & CLEAN FUELS COMPLEX of RIL
JERP, as a part of FOPE training at Reliance Industries Limited.

Reliance Industries Limited

Refinery Division

Mr .D.M.Rindani

Clean Fuels Plant

Dr. B P Singh

(SVP, HOD Meachanical)

(SGM, PMDI)

CONTENTS

Topic

Page

Acknowledgement

Introduction

Standerds

Installation dimensions E

Operational behaviour

Spring relaxation

Constant spring support

Servo hangers

13

Variable spring supports

16

Case study 1

20

Case study 2

22

Case study 3

24

Deblocking

25

Conclusion

28

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

ACKNOWLEDGEMENT

The fate of any Project is decided by the efforts put by every single person involved in the pursuance of
Project. Success can not be achieved single handedly. It is the team effort the sails the ship to the coast.
So, I would like express my deep gratitude towards everyone who helped me in completing the project. I
would like to thank my mentor Mr. Mahesh Davera (Manager Mech.) and Mr.Rateesh Venugopalan
(Manager - Mech), for spending their valuable time in assessing my progress continuously, thereby guiding
me throughout the training period. I wish to warmly thank Mr.D.M.Rindani (HOD-Mechanical) for all the
halp he assured when needed.
I express my sincere thanks to Dr. B.P. Singh (SGM, PMDI) for their moral support in course of my
training. I also thank to all contract workers, Shift In charges and Operators who co-operate with me and
help me in all my needs. Finally, I would like to thank all my colleagues in the plant for sharing their
practical knowledge.

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

SPRING SUPPORTS AN INTRODUCTION

DEFINATION
Standard supports are pipe support components, the construction of which, in form and dimension as
well as in design data rating & capacity, i.e. certified and catalogued, and which are manufactured
according to firmly established reproducible procedures
For the support of industrial piping systems, the use of standard support is regarded as well proven, up
to date technology. Only a correspondingly high level of standardization in support components can
adequately satisfy the justifiable demand of products that are technically top class and economically
attractive at the same time the complex requirement of modern pipe supports are :
o
o
o
o
o
o
o
o

Reliable functioning
Maintenance free operation
Low unit price
Simple planning with dp systems
Instant availability
Economical installation strategy
Easy to install
Supplementary supply benefits

Standard supports must fulfill the following criteria:

o
o
o
o
o
o

Component shapes are uniform and designed for optimum utilization of materials
Units are compatible regarding connecting dimensions and loading capacity
Units are catalogued and clearly identifiable by a designation system
Components are manufactured in series production
Component comply with relevant standards and international procedures
Functional capacity, suitability and durability of units are well proven

The nominal load is used for the determination of the different types of spring to be used. For the
statically determined components the nominal load corresponds to the spring elements, such as spring
hangers and constant hangers. The maximum permissible hot load lies considerably higher than the
nominal load when components are used as rigid supports, and is tied to the load capacity of the
connection threads.
Spring and constant hangers in the blocked position also count as rigid supports, whereby for cold
loads in hydrostatic tests (short duration) the emergency loads can be exploited.

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

STANDARDS
In design, stress and load calculations, as well as in manufacturing, the relevant international
standards, technical regulations and codes are taken into account. The characteristic values of
materials on whish all design calculations are based are taken from the relevant standards and
recognized technical codes.
The following codes apply:
MSS SP 58
MSS SP 69
ANSI ASME B31.1
ASME III DIV.I NF
VGB-R 510L
DIN 18800
KTA 3205.1/2/3
AD-Merkblatter
TRD-Regel
BS 3974
RCC-M
MITI 501
JEAG 4601

Pipe supports-material & design

Pipe supports-applications
Pressure piping systems
Supports for nuclear components
Standard supports
Steelwork
Nuclear regulations
Working group for pressure vessels
Techn. Regulations, steam boilers
Pipe supports
Specification for pipe supports
Technical regulations
Nuclear design regulations

USA
USA
USA
USA
GERMANY
GERMANY
GERMANY
GERMANY
GERMANY
UK
FRANCE
JAPAN
JAPAN

MATERIALS
Materials are exclusively used which corresponds to ASTM material requirements and din or din-en
norms. As a matter of principle, materials of guaranteed strength properties are used for supporting
components.
INSTALLATION DIMENSION E
For the simple determination of minimum installation lengths, the installation dimension E is given for
all components except the rods. This dimension comprises the installation length minus the engaging
length of the connecting part. For load chains, the E therefore designates the complete rod section.
To determine the total length of the rods in a load chain, all the E dimensions are to be added together.
The sum of these is then to be compared with the total installation length. If the resulting difference is
greater than the sum of the engagement depths (X dimensions), the chain selected is appropriate for
the total installation height. For load chains consisting solely of pin connections, the minimum
installation dimension follows from the sum of all E dimensions. For length adjustment in installation
condition (adjustment of pipe installation position, actuation of loading), the lower connections in

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

constant and spring hangers provide a turnbuckle function. This way, subsequent adjustment of the
installation lengths within a sufficient range is possible.
OPERATIONAL BEHAVIOR
Constant hangers type 1 are designed so that in theory no load deviation occurs over the whole range
of action. The total deviation resulting from springs, bearing friction, and fabrication tolerances is held
to within w 5% in series production. The load adjustment follows with a level of accuracy of 2%.

FN = nominal load
F min = min. load (upwards)
F max = max. load (downwards)
SN = nominal travel (incl. reserve)

For spring hangers and supports, the load alters linearly corresponding to the spring travel. The
deviation of the spring force from theoretical values, resulting from spring hysteresis and fabrication
tolerances, amounts to less than w 5% within the ordered travel.

FN = nominal load
SN = nominal travel (incl. reserve)
S = operating travel

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

SPRING RELAXATION
Conventional helical coil springs under load, depending on time and temperature factors, lose part of
their tension by relaxation (settling loss), a loss that is not inconsiderable. If no appropriate measures
are taken, for constant and spring hangers this can in the long run lead to a reduction in adjusted
ultimate load of more than 10%. To avoid that kind of problem special type of springs are used that,
through special treatment, permit no settling loss of any significance. In these springs the settling loss
normally to be expected is anticipated via the process of hot setting from a longer coil length,
producing corresponding prerelaxation.

Cold set helical coil springs

(values loosely based on DIN 2089)
Hot set helical coil springs
qualified by T.V and VGB suitability tests
(independent German authorities)
Relaxation behavior of helical coil springs

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

CONSTANT SPRING SUPPORTS

To prevent detrimental constrains in the system, thermal expansion in piping and other plant
components must not be hindered.
To compensate for vertical movement caused by thermal expansion, constant hangers provide the right
solution. Via constant hangers, the respective piping loads are constantly absorbed and transferred with
no significant deviation over the whole range of movement.
Significant load would act as harmful and uncontrolled extra loads in the system.
In this case, connection points are especially at risk because of unacceptable forces and moments. It is
vital that the constant hangers work reliably and efficiently. As this is decisive for the operational
safety and long life of the piping system.

FUNCTIONAL PERFORMANCES
The specific functional principle of constant hangers guarantees absolute consistency across the entire
travel range. This is not even affected by load adjustment. Only a minor friction force resulting from
tolerances and bearings has to be taken into account as a slight deviation. The hysteresis produced by
this is kept within very narrow limits. For normal load settings, the deviation in the operating load is
around +3%. Using proper selection process, attaining a maximum deviation of +2% is possible.
Generally permissible deviations are laid down in the following international standards:
MSS-SP 58, USA, max. +6% referring to operating load
VGB R 510 L and KTA 3205.3, Germany, max +5% referring to operating load
EN Europa Nomenentwurf, max.+5%, referring to operating load. the mean load deviation is
limited to max. +2%.
FUNCTION TEST
Before delivery of the springs to the client, all spring hangers are tested for correct function and set to
the required load. The test results are graphically and digitally plotted and are supplied to the clients if
required. The load settings are stamped on riveted aluminum name plate. In addition, the set load is
permanently marked on the load scale. Cold and hot positions are marked on the travel scale in white

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

and red respectively. The relevant travel position is directly readable on the travel scale in mm or inch.
The set load can be read from the load scale in KN.

LOAD ANALYSIS
Strict demands are placed on constant hangers to ensure reliable functions:
o Absolute consistency for all load settings
o Minimum mechanical friction
Likewise, particular requirements are to be fulfilled for the continuous monitoring of the piping system
performance.
The functional principle of constant hangers
provides the ideal conditions for fulfilling all
requirements. The principle is based on the
interplay of forces from one main spring and the
resultant force from two hooked up
compensating springs. The directions of force of
the two pre-stressed compensating springs are
opposed to each other in the form of a
parallelogram of forces.
The suspended load F acts directly on the main
spring B via the central load tube A. the force of
the compensating springs C operates as resultant
force F2, via cams D and rollers E. the forces
acts additionally on the load tube. The main
spring force F1 and resultant force F2 when the
load is moved over the travel range S. this is in
accordance with the characteristics of the
spring, and the angle and shape of the cams. The
individual components are arranged in such a
way that any change in the resultant spring
constancy correspond exactly with the
characteristic curve of the main spring. In this
way the force on the main spring is evenly
compensated for, providing constant supporting
force.
Down towards the apex of the cams the resultant
force diminishes in proportion to the increase of
the relatively low starting force of the main spring. At the apex of the cams the forces of the
compensating springs are cancelled out. The resultant is zero. At this point only the main spring carries
9

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

the load. beyond the apex, the direction of the proportionality increasing resultant force of the
compensating springs is reversed. It now reduces the relatively strong main spring force in the same
way.
The sum of, or the difference between the forces F1 and F2 at each point in the travel range is equal to
F.
LOAD ADJUSTMENT
Load adjustment is carried out by adjusting the pre-tension of the main spring. Because the
characteristic curve of the resulting compensating force and those of the main spring are identical,
only the linear displacement of the starting load F1 occurs. The force variation achieved by altering
the main spring pre-tension is the same at every point in the movement cycle. Therefore, the ultimate
load remains constant at each load setting. The useable travel changes in proportion to the load
alterations. The extremely wide load adjustment range enables to cover a broad range of applications
with a compact no. of unit sizes.

Figure showing the resultant load values after load adjustment

SPRING REALXATION
Conventional helical springs subjected to load and temperature over a period of time lose part of their
force (spring relaxation).In the long term, it can cause a reduction in the adjusted support loads of
more than 10% in constant and variable spring supports. Use of prerelaxed springs which by an
artificial aging process allow no significant settling loss. In a hot setting procedure with extended coil
lengths a corresponding pre-plastification is attained. The settling loss normally to be expected is
thereby prevented.
CORROSION PROTECTION

10

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

Constant hangers are finished with standard coating system which in conjunction with a metallically
pure treated surface offers superior corrosion protection with high mechanical stability. Bearings and
pins are made from stainless steel. All threaded parts and cams are electrogalvanized and yellow
chromatized. The spring coil surfaces are given special finishing treatment. The standard corrosion
protection for constant hangers needs no maintenance inside buildings, or in areas protected from the
weather. For components in the open and in special cases of operation, a more comprehensive
corrosion protection can be agreed on.

INSTALLATION EXAMPLES

11

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

12

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

13

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

SERVO HANGERS
Despite the use of variable spring and constant hangers, piping systems and other components are,
under certain conditions, obstructed in their thermal movement by friction or other influences. In such
cases servo hangers can be usefully employed.
Applications
In the ideal situation the weight of the piping is almost balanced out with the set load of the constant
hangers. The sum of deviations present and the additional stresses in the piping system thereby caused
then remain within the permissible harmless range. In certain cases, total deviation can exceed
permissible levels. In the form of secondary stresses it can considerably reduce the life span of the
piping or its connections in the area of creep strength depending on time.
Deviations can occur due to:
o wall thickness tolerances of the pipes, if these are not weighed individually and weight
differences are not taken into consideration
o insulation weights not exactly determinable in advance
o mechanical friction and manufacturing tolerances within constant hangers (permissible _ 5%)
o relaxed springs in constant hangers
o unpredictable random influences on pipe statics
o differences between theoretical and actual values of load distribution
A combination of deviations can normally be expected, which cumulatively can amount to
considerably high values. This is especially unfavorable with long-legged (soft) piping systems.
Vertical movements can be obstructed here, even on relatively minor individual deviations, and
partially or even totally suppressed. Apart from the extra load caused, unacceptable sagging can occur
with a reversed slope, supported by spring hysteresis from the pressure-loaded system. In addition to
possible time yield damage, this would favor dangerous water hammer effects due to a false incline. In
such cases, a sensible solution would be to complement the passively reacting constant hangers with
the actively working servo hanger. Via the hydraulic servo assistance, the piping is now actively
supported in its movement at every predetermined height.

Top: Control unit of a servo hanger

Side: Servo hanger, the whole assembly

14

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

Design and function

The basis for the servo hanger is a standard type constant hanger. To overcome load differences, it is
additionally fitted with a hydraulic auxiliary device providing additional active force in both directions
(servo assistance). As a control parameter, the temperature of the piping to be supported is normally
used. The relevant temperature is converted electronically into the corresponding position. In the
actual / theoretical value comparison procedure, the control provides for a regulated advance towards
the vertical theoretical position.

Electro-hydraulic control
The hydraulic unit and the electronic control are housed separately from each other in a switchgear
cabinet mounted near the servo hanger (max distance 16m). The hydraulic piston controlling the
movement is located in the load tube of the constant hanger.
Automatic safety switch
The electrohydraulic control is designed in such a way that only the servo assistance is lost if there is
an operational breakdown, e.g. a power failure. The unit itself would carry on operating in the normal
way as a constant hanger. For deviations in theoretical (temp.) / actual (travel) a tolerance range can be
adjusted. The control shuts off automatically if the deviation lies outside these values.
Manual shut off
For possible maintenance work in the system or at the boiler, the servo assistance can be shut on or off
by hand.

15

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

LOAD DISTRIBUTION B (SPRING DEGAGGING)

The travel stop must never be removed by force. By loosening or tightening the connecting rods with a
few turns of the load nut for constant hangers, or adjustment of the support tube for constant supports,
the locked up stress in the piping can be compensated so that the blocking pin is free.
However, the geometric layout of the piping must not be altered when balancing these stresses.
Because the adjustment of one position can lead to stressing at another location, this procedure must
be repeated if necessary at different points. For thorough control, we recommend as a matter of
principle removing the travel stop plates only after all the blocking pins are free.
If the blocking pins jam, and cannot be freed
without displacement of the piping, significant
changes in the piping load can be assumed. The
load adjustment bolts of the constant hangers and
supports can then be correspondingly set. Once
more, this should be done from position to
position, as described. If this is done correctly,
load differences can be practically balanced out
by this method. Any load adjustments must as a
matter of principle be agreed on with the technical
department responsible for the piping system. Any
new load setting values should be indicated on the
load scales and recorded.

16

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

VARIABLE SPRING SUPORT

To prevent constraints in the system, thermal expansion in the piping and other piping components
must not be hindered. The piping must therefore be supported in a correspondingly elastic manner.
Spring elements
To compensate for slight vertical displacements in the piping, spring components are used as supports.
The functioning of these components is based on preset helical coil springs which exert a variable
supporting load over the whole range of movement corresponding to the given spring characteristics.
Load variations resulting from this are limited through corresponding specifications based on stress
calculations for the piping -this depends on the sensitivity of the system.
This type, the one most frequently used, is fitted with an upper connection for
suspension. It is installed wherever the surrounding location offers a suitable
connection point and sufficient space. The upper connections can be universally
adapted with standard components to any given situation.

This type is frequently used for its simple installation, just seating it on the
existing steel. The connection is made by a rod passing through the unit.

If the installation location does not permit suspension, then this model is a
suitable alternative as a prop support. Where there is considerable horizontal
displacement of the support load, and steel slides on steel, lateral forces can
under certain conditions have an adverse effect on the operation of the support

17

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

system. To take precautions against this, the use of PTFE bearings is

recommended. In this case the counter bearing should have a stainless steel
surface.

Unlike other spring support of this type, horizontal displacement can be taken
up almost free of lateral forces by this design. This way that constraining
frictional forces are completely excluded at all levels of movement, vertical and
horizontal.

These particular components act both in tension and compression and are used
to stabilize the piping and other plant components. An additional damping effect
is obtained at the same time.

FUNCTION DIAGRAM OF VARIABLE SPRING SUPPORTS

The function diagram alongside shows the basic load

distribution of the spring with respect to travel both in
case of tension and compression

18

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

The diagram below shows the detail parts of a variable spring support -hanging type:

The hanging type variable spring support basically consists of six main components, they are the outer
can, pressure plate, turnbuckle, connecting rod, blocking units and the spring itself. The turnbuckle is
connected with the pressure plate by the help of upper connecting rod through the spring. The lower
connecting rod connects the turnbuckle with the line. As the line comes under load, the load is
transferred to the spring through the connecting rod, turnbuckle and the pressure plate. The pressure
plate compresses the spring which gets nullified by the spring force and thus the line stays in its
position

19

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

The base mounted variable type of spring support basically consists of five main parts, they are the
load tube, pressure plate, base plate tube or the guide, the blocking units and the spring itself. The
pressure plate and the load tube are internally and externally threaded simultaneously and are fixed
with one another. As the load of the line falls upon the top plate, it gradually transfers the load to the
pressure plate via the load tube. The pressure plate in return compresses the spring which actually
nullifies the load and holds the line in position.
LOAD READJUSTMENT
Spring hangers, spring supports

For spring hangers the load can be readjusted by

loosening or tightening the threaded rods at the lock nut.
For spring supports, the load can be readjusted by a
corresponding adjustment of the load tube.
Under all circumstances, however, the appropriate
technical department must be contacted before attempting
any load readjustment.

20

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

CASE STUDY 1
LOAD ADJUSTMENT OF CONSTANT SUPPORTS
SPRING NO.
: CPR 601, CPR 602, CPR 1279
SPRING TYPE
:
AREA
:C
LOCATION
: REACTOR AREA 2ND PLATFORM
PROBLEM FACED: When the deblocking of these springs were going on, the pin was not coming out
although the adjustment was done till set cold load of the spring. It needed further lot release of load to
release the pin. But structure or the base support of the spring (both CPR 601 & CPR 602) was not
allowing to release further load. So with the consultation of the vendor representative, the structural
supports of the springs were cut to provide the required E-dimension. Both of the springs were placed
on the same line. The same problem was observed in CPR 1279, hanging type constant spring support
which was placed not directly on the same line but to one of its tapings. But this was deblocked
successfully as the rating of the spring was not too high. But after deblocking, the pointer was on the
higher side of the cold load.
But at the time of reactor dryout, as the reactor started expanding, gradually the springs also showed
considerable variation in reading and ultimately crossed well beyond the hot load mark (red mark).
PROBLEM ANALYSED: After much analysis, it was found that while calculating the load of the line
at the design stage, some components were missed out which have considerable weight to create the
problem. And it was the cause of overloading the spring.
SOLUTION: After analyzing the situation, the vendor representative suggested 10% adjustment
(increment) of the load of all the three spring supports on the higher side. It was done by adjusting a
nut. There is a load adjusting scale ensuring the amount of adjustment.

ADJUSTING SCALE
ADJUSTING NUT

21

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

22

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

CASE STUDY 2
STRUCTURE MODIFICATION FOR VARIABLE SPRING SUPPORT
SPRING NO.
: SPR 1275
SPRING TYPE
: HANGING TYPE
AREA
:C
LOCATION
: REGENERATOR AREA 3RD PLATFORM
PROBLEM FACED: At the time of deblocking, the spring was not in load, so the turnbuckle was
tightened to get it deblocked. But after much effort, the spring was not deblocked. It was noticed that
the structural support, which was cantilever in type, is bending down.
PROBLEM ANALYSED: After consultation with concerned departments, it was found that the
bracing on the cantilever was missing and that had actually led to the problem.
SOLUTION: The cantilever beam was provided an additional support from the top beam to hold it in
its position and stop it from bending.

A- The structure after being sagged by the weight of the spring.;

B- The existing column through the support is taken

23

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

24

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

CASE STUDY 3
STRUCTURE MODIFICATION FOR VARIABLE SPRING SUPPORT
SPRING NO.
: SPR 117
SPRING TYPE
: HANGING TYPE
AREA
:F
LOCATION
: AT THE JUNCTION OF E RACK AND F AREA
PROBLEM FACED: While deblocking the spring SPR-117, it was found that the E-dimension i.e. the
gap between the spring and the pipe is insufficient to adjust the turnbuckle and deblock the spring.
There was no scope to shorten the connecting rod as that was also shortened to its shortest limit.
Another 100mm to 150mm was needed to deblock the spring properly.
PROBLEM ANALYSED: After much analysis it was concluded that the only way left was to move the
support through which the spring was hanging a little bit up according to the requirement. But the
spring was hanging from a CPS and the bottom part of the CPS was supporting another 16 line.
SOLUTION: It was discussed with the design department and proposed that 200mm of the top beam
of the CPS would be cut and another beam to be welded on the top of it to compensate the space
required for deblocking without weakening the strength of the CPS for supporting other pipes.

The portion of the CPS that was

added over the existing one after
cutting it
Existing CPS

Spring position is elvated

25

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

DEBLOCKING
Deblocking or degagging is very essential operation with respect to proper working of a spring
support. At first a line is erected considering various supports and essential equipments as given in the
isometric drawing. If there is a spring support, the line is generally hold with temporary supports
during the erection time. After complete erection the spring is set up at the required position. If the
spring is not block then due to the load of the line the spring will allow the line to go down until the
load is balanced by the spring force.
To avoid this the springs are pre tensioned to the required value from the manufacturing site only. And
to hold the spring at that value metallic blocks or gags are used. When the total boxup of the line is
done, they should theoretically become free and be moved. However practically many a times this
does not occur and minor adjustments are needed to make the gags free. The systematic approach to
this adjustment pertaining to the removing of the blocks is called deblocking or deggagging.
DEBLOCKING PROCEDURE FOR CONSTANT AND SPRING HANGERS
The prerequisite for the deblocking of constant and spring hangers is that the supported components
such as piping, reactors or containers, are fully installed and that the total weight is brought to bear, i.e.
o All connections must be completed
o The insulation must be fully fitted
o The piping, equipments, must be completely filled with a weight relevant medium
The geometry of the piping must not be altered when deblocking. It must be carried out line by line,
betweenbetween fixed points or connections. Possible load differences between theoretical and actual
must load be discerned.
The action taken is to be documented as follows:
1. Record hanger data from nameplate
2. Determine height measurement of piping by measuring between building structure and piping.
The measurement is to be documented on the list under the column length structure-pipe
Examples for determining the length structure-pipe is given below

26

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

3. The deblocking operation begins at the least rigid point of the piping (frequently in the
middle). The operation takes place in both directions alternately. First of all the tie rods,
adjusting nuts, adjusting spindles or turnbuckles are turned, until the blocking pieces are free or
the piping tends to lift or sink. The direction of turning is determined by the set up of the
blocking pieces. The maximum thread engagement depths are to be inspected
4. The blocking pieces may only be removed when the procedure under point 3 has been carried
out with all hangers supporting a line.

27

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

5. If all the blocking pieces for a line are free, they may be removed. If any blocking pieces are
still binding, then the point three procedure is to be repeated, possibly several times.
6. If after this the blocking pieces still cannot be removed, then the load correction procedure is to
be carried out after discussion with the respective technical department. This must be
documented on the list.
7. The blocking pieces are to be stored safely in accordance with instructions.
8. When all the blocking pieces are removed, the following must be recorded on the list:
-

blocking position (cold load)

travel position after deblocking
length structure-pipe after deblocking

SOME GENERAL MISTAKES DURING DEBLOCKING

During audits carried out after deblocking, there are some common points that comes out whish seems
to be very trivial but holds potential to hinder the proper working of the spring supports and hence the
line that is supported. To avoid these there are some simple points that is to be kept in notice at the
time of deblocking.
o Ensure the locknuts are tightened after deblocking.
o The split pins are properly opened.
o The pressure plate should not be nearly but always be exactly at the cold load position.
o There should be adequate thread of the connecting rod inside the clevis and the turnbuckle.
o The can should be tack welded to the base or bolted properly whichever applicable.
o In case of trapeze type supports, trapeze stops are must.

28

Reliance Industries Limited

Refinery Division

Clean Fuels Plant

CONCLUSION
In the concluding part of the project, it is again to be said that spring supports encompasses a wide
range of solutions ahead of rigid type of supports where vibration and considerable expansion of line
comes into play. During the tenure of two months of deputation to FCCU, where I was associated with
springs only, I have experienced the working and contents of various kinds of springs. Spring supports
of same ratings can be of various types not only with respect to hanging or pedestrial type but also
with specific positioning of the springs. There were some spring supports which had considerable
amount of travel range with respect to the spring support of the same class. We were in the degagging
group and during the tenure of degagging 689 spring supports only of piping, we came across unique
problems and mostly the solutions were brought up by us. In some cases by the design department.
The problems are generally regarding the position if the spring supports as the are situated at the
farthest extents of the plant. Some common mistakes associated with the spring supports are to be
taken care of like tightening of locknuts and opening of the split pins. If they have to be re attended
then all the arrangements starting from scaffolding building to manpower everything is required for
such a trivial thing. During this tenure, I got the rare opportunity of load setting of constant springs.
This is generally not required as the spring support already has considerable travel range. There were
spring supports situated at such positions that we had to reach there by man lifting platforms with the
help of crane.
Before concluding I would again like to thank all my colleagues and my seniors for extending their
help at each step and every time I faced a problem.

29