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Piping Stress Analysis Part

Part-II
-G.Palani
KNOWLEDGE IS NOTHING
UNLESS IT IS SHARED

7/15/2011

Table of Content

How are piping system classified by stress?


Advantage in using accurate restraint stiffness
Piping Nozzle Evaluation

Methods for analyzing equipment nozzle loads


Centrifugal Pumps and Pressure Vessel nozzle load details
Expansion Loops
Expansion Loop Examples
Thermal Expansion
Equipment Anchors
Using Coordinates to find free expansion
Expansion influencing vessel anchor end
Different Expansion Coefficients Piping System
Line Spacing Requirement
Locating Friction Balance
Attachments

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Force Nomograph
Stress Nomograph
Stress Pipeway Layout (Attached Separately)

How are piping system classified by stress?

Critical Service Piping Systems By


computer analysis
b) Intermediate Service Piping Systems
By manual calculation
c) Mild Service Piping Systems By
Visual Inspection
a)

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Expansion Loops
a)
b)
c)
d)
e)
f)

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Need for Expansion Loop


Disadvantage
Points to Remember
Expansion Loop Requirements
Locating Pipeway Loops
Multiple Loops

Points to Remember (Example & Drawings)

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Points to Remember (Example & Drawings) Cont

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Points to Remember (Example & Drawings) Cont

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Expansion Loop Examples

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Kellogg Charts CC-11 & C12 for Symmetrical Expansion


Loop sizing and Calculating Forces & Moments

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Kellogg Charts CC-11 & C12 for Symmetrical Expansion


Loop sizing and Calculating Forces & Moments (Cont.)

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Expansion Loop Example 3

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Thermal Expansion
a)
b)
c)
d)
e)
f)

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Equipment Anchors
Using coordinates to find free expansion
Expansion influencing Vessel Anchor End
Different expansion coefficients have an
effect in the piping expansion calculation
Line Spacing Requirement
Locating Friction Balance

Thermal Expansion (Example(Example-4)

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Thermal Expansion (Example(Example-5)


CaseCase
-1

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Thermal Expansion (Example(Example-5)


CaseCase
-2

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Thermal Expansion (Example


(Example-6)

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Thermal Expansion (Example


(Example-7)

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Thermal Expansion (Example


(Example-8)

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Thermal Expansion (Example


(Example-9)

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Line Spacing Requirement

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Thermal Expansion (Example


(Example-10)

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Thermal Expansion (Example


(Example-10) Cont

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Advantage in using accurate restraint stiffness

CaseCase
-1:

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CaseCase
-2:

Piping Nozzle Evaluation


Steam Turbine
Centrifugal Pumps
Centrifugal Compressors
Air Cooled Heat Exchangers
Pressure Vessels

NEMA SMSM-23
API 610
API 617
API 661
WRC 107 / 297

Methods for Analyzing Equipment Nozzle loads

Performing a test
Finite Element Analysis
International Codes and Standards

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API-610
APICentrifugal Pumps
Allowable Pump Nozzle
loading details

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AnnexureAnnexure
-F (Criteria for Piping Design)

Horizontal Pumps - Conditions of


AnnexureAnnexure
-F

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AnnexureAnnexure
-F (Criteria for Piping Design)
Cont
Vertical Pumps - Conditions of
AnnexureAnnexure
-F

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WRC Bulletin 107 Analysis


WRC Local Coordinates and Stress Points

WRC 107 should not be used if either of the following inequalities is


not satisfied:
d/D < 0.33
D/T > 50

Where:
D =mean diameter of vessel, in
d =outside diameter of nozzle, in
T =thickness of vessel wall, in

Caesar Program Table format

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ASME Section VIII Div. 2 Requirements on


WRCWRC
-107
AD-160 Fatigue Evaluation
ADOperating Experience
Rules to determine need for Fatigue Analysis of Integral parts

AD-160.1
ADADAD
-160.2
of Vessels:
ADAD
-160.3 Rules to determine need for Fatigue Analysis of Nozzles with
separate reinforcement and nonnon-integral attachments such as pad type
reinforcement, fillet welded attachment etc.
The three calculated stress intensities using WRC
WRC-107 must now be
compared to:
Pm
<
Sm
Pm + Pl
<
1.5 Sm
Pm + Pl + Q <
3.0 Sm (Sm is the average Sm at cold and hot
temperatures)
Where,
Pm Stresses due to internal pressure
Pl WRC 107 calculated stresses due
Q - 7/15/2011
WRC 107 calculated stresses due
Sm - Allowable stress intensity for the

in the vessel
to sustained loads
to expansion loads
material at operating temperature

WRC Bulletin 297 Analysis


Conditions of WRC 297 are:
d/D <
d/D<
d/t >
20
d/T>
d/T
>

0.5
20
<
5

D/T

<

2500

Where:
d
D
t
T

=
=
=
=

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outside diameter of nozzle, in


mean diameter of vessel, in
thickness of nozzle, in
thickness of vessel, in

8.

References:

Design of Piping Systems The M.W. Kellogg


Company
Introduction to Pipe Stress Analysis Sam
Kannappan. P.E.
Fluor Corporation Stress Analysis Practice
Piping Handbook - Mohinder L. Nayyar
Coade Pipe Stress Analysis Seminar Notes
APIAPI
-610, Centrifugal Pump Tenth Edition Oct
Oct2004
CaesarCaesar
-II Technical Reference Manual
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ANY QUERIES ????????

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SEMINAR ON

Piping Stress Analysis Part-II


G.Palani

KNOWLEDGE IS NOTHING, UNLESS IT


IS SHARED

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Table of Content:
1.
2.
3.

How are piping system classified by stress?


3
Advantage in using accurate restraint stiffness
3
Piping Nozzle Evaluation
5
3.1
Methods for analyzing equipment nozzle loads
6
3.2
Centrifugal Pumps and Pressure Vessel nozzle load details 6
4.
Expansion Loops
14
4.1
Expansion Loop Examples
19
5.
Thermal Expansion
26
5.1
Equipment Anchors
26
5.2
Using Coordinates to find free expansion
26
5.3
Expansion influencing vessel anchor end
27
5.4
Different Expansion Coefficients Piping System
32
5.5
Line Spacing Requirement
33
5.6
Locating Friction Balance
37
6.
Attachments
39
6.1
Force Nomograph
39
6.2
Stress Nomograph
40
6.3
Stress Pipeway Layout (Attached Separately)

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1

How are piping system classified by stress?


A. Critical Service Piping Systems By computer analysis
Pump, turbine, blower and compressor piping
Piping designed for 500F or greater
Piping designed for 1000 psig or greater
Piping greater than 24 inch diameter
Piping connected to sensitive equipment such as fired heaters, finfan coolers, reactors and boilers
Piping supported or guided from stress-relieved vessel
Jacketed piping
B. Intermediate Service Piping Systems By manual calculation
Piping designed for 250 to 499 F
Piping designed for 500 to 999 psig
Piping from 6 to 24 diameter
Nonmetallic piping
Vacuum lines
Pipeway and yard piping
C. Mild Service Piping Systems By Visual Inspection
Other piping not included in Critical and Intermediate Piping
Systems

Advantage in using accurate restraint stiffness


Caesar II default restraint stiffness is in the range of 1E12 lb/in.
Case-1:
For a rigid piping configuration, considering both ends anchor, the
following are the data for the piping configuration:
12 Sch STD, Low carbon steel pipe @ 350 F as shown below,

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According to beam theory (Guided Cantilever Method):


= Pl3 / 12EI = el
M = Pl/2
Solving for P:
P = 12EI / l3
Solving for M:
M = 6EI / l2
Solving for Se: Se = 6EI / l2Z = 6ER

/ l2

The above Se equation shows that the stress range decreases with the
square of the length of the absorbing leg, so longer the leg absorbing
the displacement, the lower the stress range.
For the above configuration (Fig. 2-20)
= 1.88 E -3 x (10 x 12) = 0.23
Se = 6 x 29 E6 x 6.375 x 0.23 / (10 x 12)2 = 17,720 psi
Note: This calculation does not consider the SIF at the elbow at the top
of the leg. If SIF is considered (for long radius elbow SIF is 2.8) the
stress range would result in 49,600 psi, which is excessive.
Case-2:
If the restraint has a lateral stiffness of 10,000 lb/in (instead of 1E12)
the thermal growth is partially absorbed by the pipe and partially
absorbed by the restraint:
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For 12 std wall pipe, I = 279.3 in^4 & Z = 43.8 in^3


Se = 2675 psi
This significantly reduces the stress range from the previous value of
17,720 psi.
Vessel nozzle stiffnesses can be calculated manually using WRC 107/297
or some equivalent.
3

Piping Nozzle Evaluation:


Piping loads on nozzles of equipment such as pumps, compressors,
turbine, and heat exchangers have the tendency to deform or overstress
equipment casing, overload bearings or cause shaft binding.
The following are the standards to calculate the allowable nozzle loads
due to piping for the below equipments,
Steam Turbine
Centrifugal Pumps
Centrifugal Compressors
Air Cooled Heat Exchangers
Pressure Vessels

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NEMA SM-23
API 610
API 617
API 661
WRC 107 / 297

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WRC Bulletin 107 (Local Stresses in Spherical and Cylindrical Shells due
to External Loadings) / 297 (Local Stresses in Cylindrical Shells due to
External Loadings on Nozzles Supplement to WRC Bulletin 107)
3.1

Methods for Analyzing Equipment Nozzle loads:


Performing a test
Finite Element Analysis
International Codes and Standards

3.2

The following are the International Codes and Standards for


evaluating the nozzle loads due to piping for Centrifugal Pumps and
Pressure Vessels,

3.2.1

API 610 Centrifugal Pumps for Petroleum, Petrochemical and


Natural Gas Industries (Tenth Edition, Oct-2004)
ISO 13709:2003, (Identical) Centrifugal Pumps for Petroleum,
Petrochemical and Natural Gas Industries

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3.2.2

WRC Bulletin 107 Analysis:


Based on the work done by Bijlaard, WRC 107 was prepared.
This Bulletin uses the finite element analysis program to
examine the stresses in vessel nozzles due to external load
attachments.
WRC Bulletin 107 (Local Stresses in Spherical and Cylindrical
Shells due to External Loadings)
Note that WRC 107 computes stresses in the vessel shell at the
nozzle/vessel interface. Stresses in the nozzle wall are not
computed. WRC 107 is used to analyze attachments to
cylindrical or spherical vessel attachments.
WRC 107 method should not be used when the nozzle is very
light or when dimensionless parameters fall outside the limits
of their respective figures.
WRC 107 should not be used if either of the following
inequalities is not satisfied:
d/D < 0.33
D/T > 50
Where:
D
d
T

=
=
=

mean diameter of vessel, in


outside diameter of nozzle, in
thickness of vessel wall, in

WRC 107 nomenclature and orientation of loads is shown below,

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Based upon various dimensional ratios of the vessel/nozzle


configuration, the engineer selects 12 parameters from 12
different curves.
These parameters are used in 15 equations to calculate 48
different stresses Circumferential membrane and bending,
longitudinal membrane and bending and shear stresses (in two
directions) at each of eight locations in the vessel (6*8 = 48
stresses).
These eight locations are the inner and outer edges (subscript l
and u respectively) of the vessels at 0, 90, 180 and 270 degrees
around the nozzle.
3.2.2.1

ASME Section VIII Div. 2 Requirements on WRC-107:


AD-160
Fatigue Evaluation
AD-160.1 Operating Experience:
When the user is considering experience with comparable
equipment operating under similar condition as related to the
design and service contemplated (Synonyms: Consider as a
possibility), fatigue evaluation shall not be performed.

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AD-160.2 Rules to determine need for Fatigue Analysis of
Integral parts of Vessels:
A fatigue analysis need not be made provided all of Condition A
or all of Condition B is met. If neither Condition A nor B is met,
a detailed fatigue analysis shall be made in accordance with the
rules of Appendices 4 and 5 for those parts which do not
satisfy the conditions.
AD-160.3 Rules to determine need for Fatigue Analysis of
Nozzles with separate reinforcement and non-integral
attachments such as pad type reinforcement, fillet welded
attachment etc.:
A fatigue analysis of pad type nozzles and non-integral
attachments need not be made provided all of Condition AP or
all of Condition BP is met. The rules of Condition AP are
applicable only to vessels constructed of materials covered by
Figs. 5-110.1 to 5-110.4. If neither Condition AP nor BP is met, a
detailed fatigue analysis shall be made in accordance with the
rules of Appendices 4 and 5 for those parts which do not
satisfy the conditions.
3.2.2.2

Caesar WRC107 Program Table Format:


The table shown below contains 72 values eight entries on
each of nine lines. The eight entries represent the stresses at
the eight locations Au, Al, Bu etc. The nine lines are three
groups of three lines the groups representing radial
(circumferential), tangential (longitudinal), and shear stresses,
while the three lines in each represent the loadings from the
pressure, sustained and expansion load cases.

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The stress terminology shown above is:


Pm - Stresses due to internal pressure in the vessel. The Hoop
and Longitudinal values of these stresses can be readily
calculated by hand. Due to the discontinuity of the nozzle cutout; there can be no hoop stresses at location C or D and no
longitudinal stresses at locations A or B. Also shear stresses in
the vessel wall due to pressure are negligible.
Pl -

WRC 107 calculated stresses due to sustained loads

Q-

WRC 107 calculated stresses due to expansion loads

Sm - Allowable stress intensity for the material at operating


temperature
The three calculated stress intensities must now be compared
to:
Pm
<
Sm
Pm + Pl
<
1.5 Sm
Pm + Pl + Q <
3.0 Sm (Sm is the average Sm at cold and
hot temperatures)
3.2.3

WRC Bulletin 297 Analysis:


297 (Local Stresses in Cylindrical Shells due to External Loadings
on Nozzles Supplement to WRC Bulletin 107)

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Conditions of WRC 297 are:
d/D
d/t
20
d/T

<
>
<
>

0.5
20
D/T
5

<

2500

Where:
d
D
t
T
4

=
=
=
=

outside diameter of nozzle, in


mean diameter of vessel, in
thickness of nozzle, in
thickness of vessel, in

Expansion Loops
Need for Expansion Loop:
One of the device used to improve the flexibility of piping are expansion
loops.
Piping systems with high temperature expands. The objective in piping
design is not to restrain this expansion but to redirect, absorb and
control its direction without overstressing the system. Loop absorbs
piping expansion.
Loops provide the necessary leg of piping in a perpendicular direction to
absorb the thermal expansion.
Expansion loops may be symmetrical or non-symmetrical.
Disadvantage:
They are safer but take more space and piping. In some cases, it may
require additional supports.

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Points to Remember:
Hotter and larger lines are placed outside as outer loops because the
longer absorbing length (H) is needed. Smaller lines with lower
temperature are placed as inside loops.
Guide is used on both sides of the loops for proper functioning, because
guide directs the expansion into the bend along the axis of the pipe,
which avoids shifting the lines sideways as shown in Fig. 5.6 below.

Three dimensional loops are widely used because this arrangement does
not block the routing of low temperature lines under the loop. The usual
raiser height is about 3 feet.

Vertical loops are placed at road crossing and sometimes are nonsymmetrical due to the location of the road.

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To control the expansion of the piping, anchor must be located at the


middle of the piping so that the expansion will be equal at the bend ends
(if the expansion is less than 10) Refer Fig. 1-29 below.

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Guides must be placed on two sides of the anchor to prevent the line
from snaking and wandering into adjacent lines Refer Fig. 1-29 above.
To reduce the structural forces:
a) Place the heavy lines near column, not near the center of a long span
as shown in fig. 1-30.
b) The anchor forces due to piping expansion must be balanced or must
be within an allowable limit as shown in fig. 1-30.

Expansion Loop Requirements:


Generally, if the total expansion in any direction on the pipeway is less
than 10, the loop could be avoided by locating the anchor in the middle
of the run.
The total expansion between the loop anchors should not exceed 12
Locating Pipeway Loops:
Ideally loops shall be located centered between anchors with equal legs
on either side of anchor as shown in fig. 1-37 below.

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When this is not practical make legs on either side of anchor as equal as
possible. By making these legs equal, the forces at the anchor should
remain nearly balanced.

Multiple Loops:
More than one loop may be required when:
Spacing between braches and neighboring lines or steel is limited.
It is impossible to make branch connections flexible enough.
When loop becomes too large to support or fit into space available.
Anchor forces between too unbalanced and steel cannot be economically
braced.

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Fig. 1-41 shows a poor arrangement, since the unbalanced forces are more
and the total expansion between loops to absorb (14) exceeds allowable
limit of 12. The alternate way of approach is to make use of multiple
loops as shown in fig. 1-42 below,

4.1

Expansion Loop Examples:


Example 1:
Find the size of the loop to absorb expansion in 200 ft of 12 carbon
steel pipe at 400F. Assume the height to width ratio.

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Answer:
Total Expansion = 200 (0.027) = 5.4
Using the nomograph, to determine loop size as shown below,
Read L2 (Bend length required to absorb expansion) in ft as 50 ft.

Assume H = W, then L2 = 2H + W = 50 ft. Thus H = W = 17 ft, making


L2 = 51 ft.
By Calculation (Guided Cantilever Method),
L2 = (3ED

/ 144 Sa) ^

Therefore,
L2 = (3*29*10^6*12*5.4 / 144*20000) ^

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L2 = 44 ft
The estimated loop size is shown in fig. 5.13 below.

Example 2:

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Kellogg Charts C-11 & C12 for Symmetrical Expansion Loop sizing and
Calculating Forces & Moments

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Example 3: Determining which of the lines requiring loops need the
largest loop, second largest, etc., by the following process:
Multiply the total expansion of each line between its proposed anchors
by the pipes moment of inertia (E). (The stiffness of a line is
measured by its Moment of inertia)
The line with the largest of these calculated numbers will require the
largest loop, the next the smaller number, the next smaller loop etc.

The above calculation shows that the 16 line should be berthed where
the 6 line is, the 10 line should be where the 16 is, and the 6 line
should be where the 2 line is. Note, on longer than normal span, loop
bowing may cause the pipe to lift off intermediate support causing
overspan.

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5

Thermal Expansion
The thermal loads that arise when free thermal expansion or contraction
is prevented by supports or anchors, loads due to temperature gradients
in thick pipe walls, and loads due to difference in thermal coefficient of
materials as in jacketed piping.
The coefficient of linear expansion of a solid is defined as the increment
of length in a unit length for a change in temperature of one degree. The
unit is 10E-06in/in/F.
The unit for mean coefficient of thermal expansion between 70F
(installation temp.) and the given temperature is given as in/100ft of pipe
length.
To convert from 10E-06in/in/F to in/100ft of pipe length, the following
relation may be used:
e, in/100ft = (coefficient) * 12 * 100 (Design temp. install temp.)

5.1

Equipment Anchors:

Most equipment is anchored to a foundation. Therefore equipment


nozzles are also anchors. Generally they are full anchors.
The anchors are mechanically rigid but may have additional expansion
when the equipment is hot.
Even if the equipment is not bolted down, the weight may be great enough
to make the equipment an anchor point.
5.2

Using coordinates to find free expansion:


The algebraic combination of lengths in any direction is the same as
the difference in anchor coordinates (In all three dimensions, i.e.
north, east and elevation). The above condition satisfies only when the
piping system temperature is uniform or same throughout the
configuration considered for finding free thermal expansion.

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The fastest way to find the free thermal expansion is to multiply the
difference between the anchor coordinates times the coefficient of
expansion. This is where the method has its greatest advantage.
Example 4:
Carbon Steel @ 300F, e = 0.0182 in/ft.
North Expansion = 190 * 0.0182 = 3.46
East Expansion = 65 * 0.0182 = 1.18

5.3

Expansion influencing Vessel Anchor End:


Points to Remember:

When finalizing the layout and plot plan the location of anchor needs to
be considered in relation to the major piping systems (large diameter
pipe, pipe coming from underground, etc).
The free thermal expansion does not depend on the piping arrangement.
The free thermal expansion depends only on the relative location of the
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anchor points. It is very useful for the layout man who is locating
equipment.
Stretching a pipe even a small amount takes a very large force.
Preventing pipe from expanding thermally takes an equally large force. In
other words, the force required to prevent the pipe from expanding is
the same as the force required to stretch it an equal amount.
The force found using the Nomograph-A can differ greatly from a
computer output, but is good enough for piping study purposes.
The following are the examples for the above points,
Example-5: (Fig. 1-11 & Fig. 1-12)
Case-1: Note that the Anchor End is at the right side of
Horizontal Vessel.

Answer:
In N-S direction the expansion to be absorbed is:
= eL (Coefficient of expansion * Length)
= 0.046 * 30
= 1.38
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In E-W direction:
= eL
= 0.046 * 20
= 0.92
Case-2: Change the anchor end of the drum as shown in figure
below, (i.e.) the anchor is shifted to left side of Vessel

Answer:
In N-S direction the expansion to be absorbed is:
= eL (Coefficient of expansion * Length)
= 0.046 * 10
= 0.46

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In E-W direction:
= eL
= 0.046 * 20
= 0.92
Conclusion: The E-W expansion did not change from the previous
example. The N-S expansion was reduced considerably by just shifting
the anchor end of the drum. Thus the case-2 requires less flexibility
and has the potential of saving pipe and fittings.
Example-6: (Fig. 1-19)
Both vessel and pipe CS at 300 F 8 Sch. 40. Calculate the thermal
forces at A & B as shown below,
Case-1: Let the Anchor end of Horizontal Vessel shall be as shown
in Fig. 1-19 below,
Note: Radial expansion of vertical vessel must be added for horizontal
expansion.

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Case-2: If the anchor end and slotted end were reversed, then
T.F.A would be:

Conclusion: Reversal of anchor end of horizontal vessel (Case-2)


causes an increase in anchor force, (i.e.) as the expansion increases,
the force required to restrain the expansion will also be increased.
Example-7: (Fig. 1-20)
SS material @ 350 F, 10 Sch. 20, with I = 114 calculate the thermal
force at A & B as shown in figure below,

Note: In this example, the guide acts as an anchor for forces in B


direction, but not in A direction.
Example-8: (Fig. 1-22)
Refer to the Fig. 1-22 below; find the horizontal and vertical thermal
forces.

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5.4

Different expansion coefficients have an effect in the piping


expansion calculation:
Taking the difference between anchor coordinates does not work
when portion of the system are different temperature and/or of
materials with different expansion coefficients.
Example-9: (Fig. 1-25)
Find the N-S and E-W thermal forces for the fig. 1-25 as shown
below,

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5.5

Line Spacing Requirement:


When there are no flanges between the corner and first guide/anchor
on the two adjacent lines, line spacing may be based on O.D of pipe or
insulation to O.D. of insulation plus expansion plus 1 clearance (Refer
Fig. 1-32) below.
= (D1+D2)/2 + thermal expansion + 1 (Clearance) + (Insu thk D1 + Insu
thk D2 (if applicable))
Where, D1 & D2 are the O.D of two adjacent pipes.

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In expansion case, usually spacing is calculated with one line hot
(operating) and one line cold (not operating).

Example-10: (Fig. 1-34)


Determine which line requires loops, based on the line spacing at the
east end of the pipeway under consideration. Assuming no extra space
is available for thermal expansion.

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Answer:
Case-1: without considering the expansion,
Refer to the Fig. 1-35 below,

A = 2.375 + 2 + 1 + 3 + 7 = 15.375 16
B = 7 + 3 + 1 + 2.25 = 13.25 14
C = Using Standard pipe spacing table = 12
D = Using Standard pipe spacing table = 19

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Without considering the expansion, the total line spacing required for
distance A, B, C & D, Total = 15.5 + 13.5 + 12 + 19 = 62
Case-2: Considering the expansion:

After the need for a loop has been established, locate the loop
anchors

Let us locate the anchor for 4 SS @ 500 F 2 IH line,


The coefficient of thermal expansion is 0.0501 in/ft.

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Allowable expansion at the right end, without increasing line spacing is
= 16 7 3 - 1 2 2.25 = 0.75
The maximum distance the anchor may be from the corner on both
ends is found by dividing the allowable movement by the coefficient of
expansion.
Left End L = 6 / 0.0501 = 120 ft
Right End L = 0.75 / 0.0501 = 15 ft
Referring to the figure 1-36, the expansion that the loop must absorb
is given as,
=700 ft 120 ft 15ft = 565 ft,
Total expansion = 565 * 0.0501 = 28.3 of expansion.
Since the maximum expansion that the loop can absorb is only 12,
which is less than 28.3, so multiple loops is required.
5.6

Locating Friction Balance:


Locating the friction balance of liquid headers that change size:

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The anchor is placed at the lines Center of Gravity.
The calculation is as follows, find the total weight and divide by two:

Locating the friction balance of vapour headers that change size:


Steam headers and flare headers should have their anchors located
without considering water in the line. Include insulation, however if
present. The method of calculating is same as above,

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6.0

Attachments:

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