1. Scope and purpose
This manual covers inspection and maintenance procedures for support and suspension systems of industrial pipelines. These include spring suspensions, rigid rods and clamps. The goal is to ensure the stability of the pipeline system, prevent excessive stresses, vibrations and destruction under the influence of static and dynamic loads. Procedures are critical to complying with industrial safety requirements and ensuring long-term equipment operation.
2. Safety measures
CAUTION: A Lockout and Tagout (LOTO) procedure must be performed for all piping related systems prior to any inspection or adjustment work. Perform work only after reducing the pressure in the pipeline to atmospheric and complete cooling of the environment. Use personal protective equipment (PPE): safety helmet, glasses, gloves, special shoes and a safety system when working at a height of more than 1.5 meters.
3. Necessary tools and materials
| Tool/Material | Specification | Quantity |
|---|
| Torque wrench | The range is 20-500 Nm | 1 |
| Vernier caliper | Accuracy 0.05 mm | 1 |
| Laser level/slope | To check verticality | 1 |
| Measuring probes | 0.05 - 2.0 mm | 1 set |
| Marker for metal | Resistant to temperatures | 2 |
| Grease (anti-corrosion) | Compatible with operating conditions | 1 tube |
| Metal brush | For cleaning surfaces | 1 |
4. Checklist before starting service
| Element | Verification | Eligibility criteria | Notes |
|---|
| Spring housing | Integrity of welds | No cracks | Use visual control |
| Traction and carving | Absence of deformations | Straight, without signs of stretching | Tilt check |
| Clamps | Adhesion density | No gaps | Check the tightening torque |
| Spring | No corrosion | Deep corrosion is unacceptable | Clean before inspection |
5. Step-by-step procedure
- Visual assessment of the condition of the supports: Inspect all elements for mechanical damage and corrosion. Avoid ignoring even minor signs of corrosion, as they may indicate structural fatigue.
- Checking the verticality of the rods: Using a laser level, make sure that the suspension rods are vertical within 3 degrees relative to the axis. The skew of the rods leads to bending moments for which they are not designed.
- Measuring spring deflection: Compare the current position of the spring load indicator with the data sheet for "cold" or "hot" condition. Allowable deviation: ±5 mm.
- Clamp tightening check: Using a torque wrench, check the tightening torque of the clamp bolts. For bolts of strength class 8.8 (M16), the torque should be 180 Nm. Undertightened bolts lead to slippage of the clamp, overtightened bolts lead to deformation of the pipe.
- Cleaning and Lubrication: Clean the threaded connections with a metal brush and apply anti-corrosion grease.
6. Checklist after service
| Test | Expected result | Actual result | Status (Pass/Fail) |
|---|
| Tightening check (torque) | 180 Nm (for M16) | | |
| Verticality of traction | Deviation < 3° | | |
| Spring position | Compliance scale | | |
7. Search and troubleshooting
| Symptom | Probable cause | action |
|---|
| Excessive deflection of the spring | Change in pipe weight or structural settlement | Calculate the load, adjust the spring |
| Traction is tilted | Thermal expansion or installation error | Adjust the position of the suspension |
| The collar slips | Insufficient tightening torque or wear | Clean, drag or replace the clamp |
8. Recommended maintenance schedule
| Task | Frequency | Duration | Skill level |
|---|
| Visual inspection | Quarterly | 30 min | Category I technician |
| Tightening and lubrication check | Every year | 1 hour | II category technician |
| Full load test | Once every 3 years | 2 hours | Mechanical engineer |
9. Spare parts
| Description of the part | Typical specification | UNITEC Category |
|---|
| Spring block | Load 500-2000 N | Pipeline supports |
| Threaded collar | Diameter 50-200 mm | Fastening |
| Threaded thrust | M16, steel 8.8 | Fastening |
To order spare parts, visit: https://www.unitecd.com/e-catalog/
10. Links
- DSTU EN 13480-3:2018 Industrial metal pipelines.
- ISO 12944 Paints and varnishes. Protection of steel structures from corrosion.
- Technical documentation of the manufacturer of support systems.
