Teledyne Brown Engineering has extensive experience in the engineering and fabrication of large process pipe ways and structures. TBE’s capabilities include performing seismic and stress analysis, providing detailed shop drawings based on customer high-level designs, and verifying manufacturability of customer designs. TBE has manufactured numerous pipe ways to ASME NQA-1 and Section III quality controls and delivered them to customers. TBE has also developed specialized cargo trailers for the delivery of large pipe ways.
The piping structures that Teledyne Brown has designed and manufactured have been up to 40 feet in length and greater than 25,000 pounds with tolerances of 30 thousandths of an inch. Some of these structures are frame and pipe only, while others have included electrical power and control modules, process flow valves, and instrumentation. These pipe ways have been designed for indoor use and outdoor use with weatherproof insulation panels. Pipe way modules can be manufactured in both vertical and horizontal configurations.
Teledyne Brown designs pipe ways for installation using flanged piping or for field welding of the piping. Field-welded structures require precision cutting, welding, and integration to maintain tight tolerances on installation dimensions. TBE engineers and welders are also available for support in the field.
We have designed and built a facility specifically for manufacturing and cleaning frames and pipes and can perform integration of the units at our facility prior to shipment to the installation site. The facility layout was done to maximize the efficiency of movement of all elements of the structure and piping through the facility with the least amount of handling, minimizing costs, and also to maximize cleanliness as required for each piping array.
Our facility is outfitted with in-house designed and built systems for the manufacture, cleaning, and testing of pipe ways, including cleaning systems to clean hydrocarbons from stainless-steel pipe (4- to 20-inch diameter) to less than 50 parts per million.
Teledyne Brown also designed and built a pipe flue pulling machine to eliminate the use of sockolets and weldolets and allow laminar flow of gases within the pipes and eliminate buildup of corrosive chemicals. This system requires minimal setup and locates, drills, and pulls flues at preset dimensions across stainless-steel piping lengths. It allows repeatable performance in locating piping interconnection points and allows for autogenous welding of the piping connections.
We designed and built an electrical testing unit for use on pipe ways with electrical wiring and components. This tester attaches to specific electrical connections and automatically checks for continuity, shorts, and proper resistance values; thus, verifying electrical installation and performance prior to shipment.
TBE maintains an ASME Nuclear Quality Assurance Manual that governs the design, manufacture, test, and certification requirements for our ASME Section III (N-Stamp, NS-Stamp, and NPT-Stamp) and ASME Section VIII, Division 1 (U-Stamp, UM-Stamp) manufacturing programs. Our Quality Plan meets all requirements of a 10CFR50, Appendix B, Quality Program. The Quality Plan also provides structure to support the monitoring and reporting requirements of 10CFR21.
Our NQA-1 Quality Plan addresses the requirements and subsequent controls to provide full material traceability throughout the manufacturing process. TBE uses a series of unique shop travelers and piece-mark mapping on as-built drawings to provide the customer with a full map of all materials used, including relevant hardware, fasteners, and weld filler materials. This data, partnered with the associated Material Test Reports, provides a package ready for Commercial Grade dedication activities that TBE can also perform. In accordance with NQA-1 requirements for qualification and certification of all inspection, test, and nondestructive examination personnel, this program is governed by the strict qualification and certification requirements set forth in the ASME B&PV Code, Sections III and VIII, including the maintenance of inspection/test/examination continuity logs and annual reviews performed by TBE’s in-house Level III. If required, TBE will develop a program-specific Quality Assurance Plan to address all customer requirements.
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