Tahir. Aric COADE eet PIPE STRESS ANALYSIS SEMINAR NOTES Notice: Unless otherwise noted herein, the information contained in these course notes is proprietary and may not be translated or duplicated in whole or in part without the expressed written consent of ENGINEERING PHYSICS CORPORATION, 12777 Jones Ra., Suite 480, Houston, Texas 77070. Copyright (c) 1985 - 1993 COADE, Inc.SECTION 11.0 11 13 14 15 Intra Theo: Lt 112 113 lid Fatigue Failure 12.1 1.22 12.3 1.2.4 125 Stress Intensification Factors .. Weldi Code 15.1 152 15.3 15.4 155 15.6 157 158 159 15.1 ie COADE Pipe Stress Analysis Seminar Notes Section 1 Table of Contents duction to Pipe Stress Analysis ry and Development of Pipe Stress Requirements Basie Stress Concepts ... : 3-D State of Stress in the Pipe Wall Failure Theories Maximum Stress Intensity Criterion Fatigue Basics Fatigue Curves... Effect of Fatigue on Piping Cyclic Reduction Factor Effect of Sustained Loads on Fatigue Strength ling Research Couneil Bulletin 330 Compliance Primary vs. Secondary Loads -acsncrcetnnnenen Code Stress Equations BS1.1 Power Piping : 31.3 Chemical Plant and Petroleurn Refinery Piping ASME Section III, Subsections NC & ND (Nuclear Class 2 & 3) B31.4 Fuel Gas Piping... B31.8 Gas Transmission and Distribution, Piping C Code. Canadian 2183/2184 Oil/Gas Pipeline Systems RCC-MC 10 Stoomwezen 1 Special Considerations of Code Compliance 1.5.12 Evaluation of Multiple Expansion Range Cases ald 14-15 16 218-19 .. 20 220 22 os 24-25 25 26 28-38 34 43 ABS 45-46 46 AT 49-50 51 52 54 55 36 56-59 53COADE Pipe Stress Analysis Seminar Notes 1.0 Introduction to Pipe Stress Analysis In order to properly design a piping system, the engineer must understand beth a system's behavior under potential loadings, as well as the regulatory requirements imposed upon it by the governing codes. A system’s behavior can be quantified through the aggregate values of numerous physical parameters, such as accelerations, velocities, displacements, internal forces and moments, stresses, and external reactions developed under applied loads. Allowable values for each of these parameters are set after review of the appropriate failure criteria for the system, System response and failure criteria are dependent on the type of loadings, which can be classified by various distinctions, such as primary vs. secondary, sustained vs. occasional, or Static vs, dynamic The ASME/ANSI B31 piping codes are the result of approximately 8 decades of work by the American Society of Mechanical Engincers and the American National Standards Institute (formerly American Standards Association) aimed at the codification of design and engineer- ing standards for piping systems. The B31 pressure piping codes (and their successors, such as the ASME Boiler and Pressure Vessel Section II nuclear piping codes) prescribe minimum design, materials, fabrication, assembly, erection, test, and inspection requirements for piping systems intended for use in power, petrochemical/refinery, fuel gas, gas transmission, and nuclear applications Due to the extensive calculations required during the analysis of a piping system, this field of engineering provides a natural application for computerized calculations, especially during the last two to three decades. The proliferation of easy-to-use pipe stress software has hada two-fold effect: first, it has taken pipe stress analysis out ofthe hands of the highly- paid specialists and made it accessible to the engineering generalist, butlikewise it has made everyone, even those with inadequate piping backgrounds, capable of turning out official- looking results ‘The intention of this course is to provide the appropriate background for engineers entering the world of pipe stress analysis. The course concentrates on the design requirements (particularly from a stress analysis point of view) of the codes, as well as the techniques to be applied in order to satisfy those requirements. Although the course is taught using the CAESAR II Pipe Stress Analysis Software, the skills learned here are directly applicable to any means of pipe stress analysis, whether the engineer uses a competing software program or even manual calculational methods. Why do we Perform Pipe Stress Analysis? There are a number of reasons for performing stress analysis on a piping system. A few of these follow: 1 - Inorder to keep stresses in the pipe and fittings within code allowable levels. 2 - In order to keep nozzle loadings on attached equipment within allowables of manufacturers or recognized standards (NEMA SM23, API 610, API617, etc.)COADE Pipe Stress Analysis Seminar Notes 3. + Inorderto keep vessel stresses at piping connections within ASME Section VIII allowable levels. 4 - Inorder to calculate design loads for sizing supports and restraints. 5 - Inorder to determine piping displacements for interference checks. 6 - Inorder to solve dynamic problems in piping, such as those due to mechanical vibration, acoustic vibration, fluid hammer, pulsation, transient flow, and relief valve discharge. 7 - Inorder to help optimize piping design. Typical Pipe Stress Documentation Documentation typically associated with stress analysis problems consists of the stress isometric, the stress analysis input echo, and the stress analysis results output. Examples of these documents are shown in Figures 1-1 through 1-5 on subsequent pages. The stress isometric (Figure 1-1) is a sketch, drawn in an isometric coordinate system, which gives the viewer a rough 3-D idea of the piping system. The stress isometric often summarizes the piping design data, as gathered from other documents, such as the line list, piping specification, piping drawing, Appendix A (Figure 1-2) of the applicable piping code, etc. Design data typically required in order to do pipe stress analysis consists of pipe materials and sizes; operating parameters, such as temperature, pressure, and fluid contents; code stress allowables; and loading parameters, such as insulation weight, external equipment movements, and wind and earthquake criteria. Points of interest on the stress isometric are identified hy node points. Node points are required at any location where itis necessary to provide information to, or obtain information from, the pipe stress software. Typically, node points are located as required in order to 1 + define geometry (system start, end, direction changes, intersection, etc.) 2 - note changes in operating conditions (system start, isolation or pressure reduc- tion valves, etc.) 3. - define element stiffness paramete: rigid elements, or expansion joints (changes in pipe cross section or material, 4 - designate boundary conditions (restraints and imposed displacements) - specify mass points (for refinement of dynamic mode!) 6 - note loading conditions (insulation weight, imposed forces, response spectra, earthquake g-factors, wind exposure, snow, etc.) 2 - retrieve information from the stress analysis (stresses at piping mid spans, displacements at wall penetrations, ete.) 12COADE Pipe Stress Analysis Seminar Notes ‘The input echo (Figure 1-3) provides more detailed information on the system, andismeant to be used by the engineer in conjunction with the stress isometric. ‘The analysis output provides results, such as displacements, internal forces and moments, stresses, and restraint loadings at each node point of the pipe, acting under the specified loading conditions. CAESAR II provides results in either graphic or text format; Figures 1-4 and 1.5 present stress and displacement results graphically. The output also provides a code check calculation for the appropriate piping code, from which the analyst can determine which locations are aver stressed. SSemi Material ates Gr.B SH 0708 deg. = 16,SAB pei 22,008 pai Flue Gaz Support Fron Touer “yee Computed thernal expansion of the vessel is Nya, 47.2608-6 Inin/deg.F. at a tenp of 820 deg.F. | Exchanger Node 108 is 28.08 ¢. above vessel skint tee Disp. @ 188 = (820-78)dey .F(A? 263E-S)in/invdege (20.08) AZ Ire. intt. = 3.121 in Disp. © 128 = (828-78)¢17 2698-6) (28.08~6.5-15)(12) = 1.8 in. Figure 13COADE Pipe Stress Analysis Seminar Notes Figure 1-2 14COADE Pipe Stress Analysis Seminar Notes CAESAR II VERS 3.18 COBNAME:SSEM2 DEC 30, 1992 3:05 am Pase 1 PIPE DATA From 100 PIPE Dia= 20.000 In. wall= . GENERAL 700 F Pls 125.9000 ib./sq.in. Mat= (1)LOW CARBON STEEL F= 27,900,000 >b./sq.in. v= 292 Density .2899 Ib./eu. in. we RIGIO. Wetght= 3,290.00 1b. DISPLACEMENT Node 100 DX .000 fn. Y= 3.121 tn. DZ= .000 in. -RX= .000 RY= 000 RZ= .000 ALLOWABLE STRESSES 831.3 igs0) Ineul= 2.000 tn I= 16,600 1b./sq.in From 105 7 BEND at "TO" end Radius= 30.000 in. (LONG) Bend AngTe~ 90.000 Angle/Node @1- 45.00 102 Angle/Node @2= .00 108 From 110 To 118 D BEND at "To" end Radius= 30.000 tn. CLONG) Bend Angie» $0,000 Angle/Node @1= 45.00 114 Angle/Node @2= 00 113 From 215 To 120. DY# DISPLACEMENTS, Node 120 DX~ FREE RI= FREE From 120 To 125 0 BENG at "To" eng Radius~ 30.000 in. (LONG) fend Angle= 90.000 Angle/Wode @1= 45.00 124 Angle/Node @2= .06 123 3.000 ft. From 125 To 130 OX- 35.000 ft. RESTRAINTS, Node 130 4¥ From 130 To 135 ox= 35.000 ft. RESTRAINTS, Node 135 +¥ From 135 To 140 Dx= RESTRAINTS Node 140 +¥ From 140 To 145 DX 20.000 ft. iD at “TO” end Radtus= 30.000 in. (L Angle/Wode @2= .00 143 00 144 NG) Bend Angie» 90.000 Angle/Node @1= From 145 To 180 RESTRAINTS Node 150 ANC +12,000 ft Figure 1-3COADE Pipe Stress Analysis Seminar Notes case us 2 caxpyoaep-02 £ COPE)U-DIS-TL-Pt FIUESSSDN DEC 41982 22:47am UERSTRESSED eNDES, Figure 1-4 FILE:SSPM DEC 4,1952 12-4¥0n ax, ists. x Figure 1-5 16 wor ves orst naSTH eine Jos rig Sms sya ERIN fxn STRESS coun BxnIN ‘ons xe STRESS ese wit owes, verur shucey nent Snow Coos ania, Lae HabeCOADE Pipe Stress Analysis Seminar Notes What are these Stresses? The stresses calculated are not necessarily real stresses (such as could be measured by a strain gauge, forexample), but are rath ‘code” stresses. Code stress calculations are based upon specific equations, which are the result of 8 decades of compromise and simplification, ‘The calculations reflect: ae Inclusion or exclusion of piping loads, based upon convenience of calculation or selected failure. In fact the result may not even represent an absolute stress, value, but rather a RANGE of values. Loading type — these are segregated, and analyzed separately, as though they occur in isolation, even though they actually are present simultaneously. Magnification, due to local fitting configuration, which may in reality reflect a decrease in fatigue strength, rather than an increase in actual stress. Code committee tradition — every code is a result of a different set of concerns and compromises, and therefore may appear to be on a different branch of the evolutionary ladder. Because of this, every code gives different results when calculating Stresses. A summary of significant dates in the history of the development of the piping codes is presented below: 1915 1926 1955 1969 1971 1974 1978 1987 - Power Piping Society provides the first national code for pressure piping. - ‘The American Standards Association initiates project B31 to govern pressure piping. - Markl publishes his paper “Piping Flexibility Analysis”, introducing piping analysis methods based on the “stress range”. - First computerized analysis of piping systems. - Congress enacts the Natural Pipeline Safety Act, establishing CFR 192, which will in time replace B31. for gas pipeline transportation. - Introduction of ANSI B31.7 code for Nuclear power plant piping. + Introduction of ASME Section IT for Nuclear power plant piping. - Winter Addenda B31.1 moves away from the separation ofbending and torsional moment terms in the stress calculations and alters the intensi- fication factor for moments on the branch leg of intersections. - ANSI B317 is withdrawn - Welding Research Council Bulletin 380 recommends changes to the B31.1, B31.3, and ASME III Class 2 and 3 piping endes.COADE Pipe Stress Analysis Seminar Notes 1.1 Theory and Development of Pipe Stress Requirements 1.1.1 Basic Stress Concepts Normal stresses: Normal stresses are those acting in a direction normal to the face of the crystal structure ofthe material, and may be either tensile or compressive in nature. (In fact, normal stresses in piping tend more to tension due the predominant nature of internal pressure as a load cage.) Normal stresses may be applied in more than one direction, and may develop from a number of different types af loads. For a piping system, these are discussed below: Longitudinal stress: Longitudinal, or axial, stress is the normal stress acting parallel to thelongitudinal axis ofthe pipe. This may be caused by an internal force acting axially within the pipe: SL = Fax! Am Where: Sp = longitudinal sires, psi Fax = internal axial force acting on cross-section, Ib Am = metal cross-sectional area of pipe, in? 2 = = nd? -4)2)/4 a3 = xdgt 4, = outer diameter, in 4 3 @ = inner diameter, in > dj, = mean diameter, = (do + dj)/2COADE Pipe Stress Analysis Seminar Notes A specific instance of longitudinal stress is that due to internal pressure SL Internal Pressure: SL Figure 1-7 SL = PAi/ Am Where: P = design pressure, psig Aj = internal area of pipe, in? = rd2/4 Replacing the terms for the internal and metal areas of the pipe, the previous equation may be written as: SL = Pd2/(d,2- 42), or: 8, = Pd2/4dat For convenience, the longitudinal pressure stress is often conservatively approximated as: S. = Pdof4t Another component of axial normal stress is bending stress. Bending stress is zero at the neutral axis of the pipe and varies linearly across the cross-section from the maximum, compressive outer fiber tothe maximum tensile outer fiber. Calculating the stress aslinearly proportional to the distance from the neutral axis: Variation in Bending Stress Cross Section “ ve stress Neutral Axis 18COADE Pipe Stress Analysis Seminar = Mpc/I Where My = bending moment acting on cross-section, in-Ib ¢ = distance of point of interest from neutral axis of cross-section, in I = moment of inertia of cross-section, int = nyt dy4)/ 64 Maximum bending stress occurs where c is greatest — where it is equal to the outer radius Snax = MpRo/I = My/Z Where: R, = outer radius of pipe, in z section modulus of pipe, in3 TR, Summing ali components of longitudinal normal stress: SL o= Fax/Am+Pdo/4t+ M/Z ~~ Hoop stress: There are other normal stresses present in the pipe, applied in directions ‘orthogonal to the axial direction. One of these stresses, caused by internal pressure, is called hoop stress. This stress acts in a direction parallel to the pipe circumference. Figure 1-9 ‘The magnitude of the hoop stress varies through the pipe wall and can be calculated by Lame'’s equation as: Sy = Pie? +r x62 / 12) / (ro? - 472) 1-10COADE Pipe Stress Analysis Seminar Notes Where: Sx = hoop stress due to pressure, psi m= inner radius ry = outer radius of pipe, in r = radia] position where stress is being considered, in ‘The hoop stress can be conservatively approximated for thin-wall cylinders, by assuming that the pressure force, applied over an arbitrary length of pipe, 1 (F = P d]), is resisted uniformly by the pipe wall over that same arbitrary length (Ar, = 2 t 1), or: SH = Pdl/2tlor: Su = P di/2t, or conservatively: Sq = Pay/2t Radial stress: Radial stress is the third normal stress present in the pipe wall. It acts in the third orthogonal direction, parallel to the pipe radius. Radial stress, which is caused by internal pressure, varies between a stress equal to the internal pressure at the pipe’s inner surface anda stress equal to atmospheric pressure at the pipe’s external surface. Assuming that there is no external pressure, radial stress may be calculated as: radial stress due to pressure, psi wn 2 4 Note that radial stress is zero at the outer radius of the pipe, where the bending stresses are maximized. For this reason, this stress component has traditionally been ignored during the stress calculations. Shear stresses: Shear stresses are applied in a direction parallel to the face of the plane of the crystal structure of the material, and tend to cause adjacent planes of the erystal to