Piping Stress Analysis

Overview
E
What is Flexibility Analysis ?
E
Analytical Method to calculate Displacement & Stresses
E
Guidelines for lines connected to Critical Equipment
E
Fundamentals of Primary & Secondary stresses
E
Spring Supports
E
Various Load Cases
Stress Analysis
E
Expansion Joints
E
Checking Flexibility using Nomographs
E
Fundamentals of Buried Pipe Analysis
E
Stress Analysis using CAESAR-II
E
Stress Analysis- Responsibilities & Methodology


Flexibility
Temperature
COLD
HO
T
Stress Analysis
Not Flexible
Flexible
More Flexible
E
What is Flexibility of the Piping System?
Ability to absorb thermal growth of the piping system


Overview
E
What is Flexibility of the Piping System?
Stress Analysis
Piping system shall be designed to have sufficient
flexibility to prevent pipe movements from causing
failure from overstress, leakage at joints or detrimental
distortion of connected equipment resulting from
excessive thrusts and moments
E
How to provide Flexibility in the Piping system ?
By change in direction using BENDS, utilising
Expansion joints
Ability to absorb thermal growth of the piping system
E
What code states about Flexibility in the Piping system ?
E
HOW to conclude whether system is Flexible or not ?


-
Sustained (Primary) Stresses <= SH or SC

Piping system- flexible and safe only IF following criteria are satisfied
-
Thermal stresses <= Allowable Stress Range
-
Flange Leakage
-
Max Thermal Displacement- Axial / Lateral
-
Pipe Sagging
-
Nozzle Loading
-
Vessels and Heat Exchangers
-
Support Loading
Criteria Comparison Basis
-
Centrifugal Pumps
-
Centrifugal Compressors
-
Reciprocating Compressors
-
Steam Turbines
-
Air Cooled Exchangers
ANSI B 31.3
Project Design Basis
Project Design Basis
Project Design Basis
Project Design Basis
Project Design Basis
API-610
API-617
API-618
API-661
NEMA-23
Project Design Basis
Stress Analysis
Acceptability Criteria


Types of STRESSES in the Piping System

Primary Stresses

Direct Shear and Bending in nature

Caused due to-

+
Dead Weight
+
Internal Pressure
+
Occasional Load

Pipe

Fluid

Piping Component

Snow/ Ice

Wind

Seismic Load

PRV Thrust

Secondary Stresses

Bending (cyclic) in nature

Caused due to-

+
Thermal Expansion

Equipment

Piping System

Local Stresses

Localised Bending and Shear in nature

Caused due to-

+
Local load like load on welded lug on pipe
Stress Analysis


Code Allowable STRESSES

Primary Stresses

Checking Criteria

Secondary Stresses
-
Induced Stresses <= Sh or Sc
? How to FIND Sh and Sc
Sc = Allowable Stress at amb.Temp.
Sh = Allowable stress at elev. Temp.
Table A-1 for Metallic Piping
Table K-1 for High Press Piping.

Checking Criteria
-
Induced Stresses <= Sa
? How to FIND Sa
Sa = Allowable Stress Range
Refer B31.3
Sa = f x ( 1.25 Sc + 0.25 Sh )
Refer
B31.3
Stress Analysis


Stress Range- Definition
COLD
HOT
HOT OPERATING COLD COLD

As
Installed
Outer fibre-Tension

At Elbow >>

Thermal exp.
Inner fibre- Compr.

Bending stresses
diminishes due to
plastic deformations
Stresses Relaxed

At Elbow >>
Outer fibre-Compr.

At Elbow >>

Thermal contraction
Inner fibre- Tension
Stress Loading type - CYCLIC
Failure type - FATIGUE
Failure time - Number of Cycle
Stress Analysis
Conclusion ?


Allowable Stress Range
Allowable Stress Range ( Sa) = (1.5 x Sh) + (1.5 x Sc) = 1.5 ( Sc +Sh )
Yield Stress ( Sy ) =1.5 x Allowable Tensile Stress ( Sc or Sh)
Provision of Primary stresses = Sh
Reduced allowable = 1.25 ( Sc + Sh)
To account for simplification in calcn.
To account for localised stresses
Allowable Stress Range ( Sa) = (1.25 Sc + 0.25 Sh ) x f
f = Stress reduction factor
= 1 For life cycle up to 7000
= 0.9 For life cycle 7001 ~ 14000
= 0.8 For life cycle 14001 ~ 22000
= 0.7 For life cycle 22001 ~ 45000
= 0.6 For life cycle 45001 ~ 100000
= 0.5 For life cycle 100001 & over
Stress Analysis
COLD
HOT


Stress Evaluation
4
Temperature
COLD
HOT
L
= x L
Linear Coef of thermal expn.
( Ref. B31.3, Table C-1 )
Stress = Strain x E
Young Modulus of Elasticity
( Ref. B31.3, Table C-6 )
Force = Stress x Area
= 48 (L)
2
S / E D
E D / 48 (L)
2
S =
Guided Cantilever Method
Stress Analysis


Stress Evaluation-In & Out Plan Bending, SIF
Mi
Mt
Mo
For safe design Se < = Sa
Sb = ( Ii x Mi )
2
+ ( Io x Mo )
2
Z
Ii = SIF factor- In Plane
Io = Sif factor- Out Plane
Z = Sectional Modulus of Elasticity
= 3.142 x ( Do
3
- Di
3
) / 32
B 31.3 Table D-1
St = Mt / ( 2 x Z )
Se = Sb
2
+ 4 x St
2
Stress Analysis


Simplified method to check piping system flexibility
Basis - Code B 31.3 para 319.4.1
COLD
HOT
U

L
D x
( L - U )
2
< = K
I F Then Piping is Flexible
D = Pipe OD ( mm )
= Resultant Displacement ( mm )
L = Developed Length ( mtrs )
U = Anchor Distance ( mtrs )
K = 208.3
Limitations

Only two point of fixation

No change in pipe size

No intermediate restraint
Stress Analysis


Other Methods to check the flexibility

Using Nomographs

To perform quick flexibility check

To estimate preliminary anchor loading for civil structural design

Highly versatile application program

To do preliminary exp.. loop sizing on pipe rack at early stage of the job

To review visual analysis lines to avoid expensive CAESAR analysis

Results are acceptable to world wide Engineering companies

Based on Finite Element Analysis Method

Stress Analysis

Using Computer application - CAESAR-II

Initial Review

Review Piping Specification

Review Piping Study Drawing around critical equipment

Identify critical civil structural requirements

Review all applicable project standards

Prepare Preliminary Stress Critical Line List

Quick check using Excel spreadsheet for Pipe Wall and Br. Reinf. Calculation

Review Pipe-Rack study layout- Establish preliminary exp.. loop location

Establish preliminary Pipe-rack loading for structural design

Detailed Review

Identify CAESAR Stress Models- Include group of lines in single model

Perform detailed stress analysis based on issued stress critical line list

Analyse visual check lines using simplified manual techniques

Communicate with civil, Vessel and Mechanical groups for loading

Final Approval

Freeze the stress model based on final isometrics

Documentation of Input and Output Reports

Stress Analysis
General Working Procedures


Identify Stress
Critical Lines-
Stress Critical Line
List
Review
Stress
Isometric
Revise the
Piping study &
Isometric
Freeze
Supporting
arrangement
Approve
the Stress
Isometric
Nozzle
loading &
Civil Loading
Acceptable ?
?
Yes
No
Stress Analysis
General Working Procedures


Responsibilities of Stress Engineers

Nominated by Chief Piping Engineer

Responsible for all Stress and Support related activities

Ensure work carried out per Procedures and Design Basis

Establish the Contract Design Data and Design Philosophy

Issue Stress and Support Design Note

Establish Stress Critical Line List

Stress Group Progress Reporting, Man-hours allocation and

Forecast

Raise the Change order to reflect additional work

Supervise Stress and Support activities

Review Piping Specification for Pipe wall thickness and Branch Calc

Job close-out report for stress and support group

Stress Analysis
C Stress Lead Engineer

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Nominated by Chief Piping Engineer/Lead Stress Engineer

Carry out Flexibility analysis

Identify all the load cases to be considered in analysis

Review Study Drawing to ensure sufficient flexibility in critical piping

Identify and review all critical piping supports

Summarise Equipment Nozzle Loading communicate to others

Perform flange leakage calculation for high pressure piping

Communicate critical support loading to Civil

Prepare Spring Schedule/Bellow Specification for procurement

Identify requirement of reinforcement pad due to stress consideration

Decide on position of Fixed saddle of horizontal Heat Exch.. and Vessels

Review Vendor data regarding nozzle loading etc..

Documentation of Analysis Reports

Stress Analysis
Responsibilities of Stress Engineers
C Stress Engineer

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SPRING Supports

Spring Hangers/ supports

E
Why required ? ? ?

Variable Type

Constant Force Type
E
Types of Spring supports
E
Principle of working
E
Terminology

Cold Load

Hot Load

Spring Rate

Travel
E
Instruction for Field Installations
E
Technical Specification
Stress Analysis


Expansion Bellows
E
Why to use ? ? ?
E
Instruction for Field Installations
E
Why NOT to use ? ? ?

Metallic Bellow
E
Material of Construction

Non- Metallic ( Rubber / Fabric )

Axial
E
Types of Metallic Bellows

Universal

Tied

Swing

Hinged

Gimbal

Pressure Balanced
E
Selection Criteria
E
Technical Specification
Stress Analysis
E
Back Thrust of Un-tied bellow


Piping Supports



Pipe Supports
E
Purpose of Support
E
Pipe support Instructions and Design Guide
E
Type of Supports
E
Pipe support Standard
E
Pipe Support - Trunnion Calculation
E
Pipe Support - Span Table

Overview


Purpose of Pipe supports

Purpose
E
To Support dead weight of Piping system
E
To absorb wind load and Seismic load
E
To absorb Vibration in the Piping system
E
To Suppress the Noise level in the Pulsating Piping systems
E
To take Expansion load in the Piping system
E
To absorb Hydraulic Thrust in the Piping system
E
To Support the system during Shut down/ Maintenance Cond.
E
To absorb the Pressure Thrust of Bellow
E
To minimise Pipe Sagging

Pipe Supports


Types of Pipe supports

Based on Functions
E
Loose or Resting supports
E
Longitudinal Guide Supports
E
Transverse Guide Supports
E
Anchor Supports
E
Limit Stops

Welded Type

Non- Welded Type

Based on Construction
E
Rigid Support
E
Adjustable Supports
E
Elastic Supports

Bolted Type

Welded Type

Constant Type

Variable Type

Snubber Type

Pipe Supports


Types of Pipe supports- Details
E
U-Bolts and Clamps
E
Shoe
E
Rod Hangers

Welded Type

Clamped Type

Secondary Supports
E
Attachment from Steel Structures
E
Attachment from RCC Structures
E
Attachment from Equipment

Primary Supports
E
Attachment from Grades

Other Supports
E
Trunnion Supports
E
PTFE Sliding Supports

Pipe Supports