PIPE STRESS ANALYSIS WORK

By: Tengku Syahdilan

Senior Piping Mechanical Engineer
PT KBR Engineers Indonesia

AGENDA

1.
2.
3.
4.
5.
6.
7.
8.

Why Do We Perform Pipe Stress Analysis?.

Pipe Stress Engineer Scope of Work.
Theory of Pipe Stress Analysis.
Pipe Supports.
Applicable Codes.
Pipe Stress Analysis using Caesar II 5.20.
Code Compliances and Nozzle Evaluation.
Designer Responsibilities Related to Stress Engineering
Work.

1. Why Do We Perform Pipe Stress Analysis?

To keep stresses in the pipe and

fittings within code allowable.
To keep nozzle loadings on attached
equipment within allowable of
manufacturers or recognized
standards (API 661, API 650 etc)
To calculate design loads for sizing
supports and restraints.
To determine piping displacements
for interference checks.
To solve dynamic problems in
piping, i.e.: mechanical and acoustic
vibration, fluid hammer, pulsation,
transient flow and relief valve
discharge.
To optimize piping design.
To prevent flange leakage joint.

2. Pipe Stress Engineer Scope of Work

Develop Critical
Lines List
-Depend on Client
Specification.

Review Stress
Isometric

Acceptable?

-Category 3 (Computer Analysis).

-Category 4 (Approximate Method).
-Category 5 (Visual Exam.).

No

Revise the Piping

Layout & Isometric
-Modify pipe support type
and location.

Yes

-Add elbow to increase

piping flexibility.

Review and
Comment on
Conceptual
Studies

Review 3D
Model and
Support Scheme

-Stresses are within allowable.

-To prepare pipe support selection.

-Nozzle loads are within allowable.

-To select pipe support based on

pipe support selection criteria.

-Anchor and guide support location are

already fixed and already informed the
loading values to Civil Department.

-To check the 3D Model is comply

with the latest stress calculation or
not.

Review and
Approve the
Stress Isometric

Pipe Stress Analysis Category

Method of Analysis:
1.

Category 3
Using computer program
such as: Caesar II (Coade),
Autopipe (Bentley), PIPANL3 (SSD) etc.

2.

Category 4
Using approximate methods
such as: the Kellogg,
Grinnell or Tube Turn
methods.

3.

Category 5
Visual inspection with or
without the aid of guided
cantilever chart or similar
short cut methods.

Ref: KBR Design Manual

Subject No: 4100

3. Theory of Pipe Stress Analysis

3. 1. Stress-Strain Curve

x E
Where:
= Stress (kg/cm2)
= Strain
E = Youngs Modulus (kg/cm2)
Allowable stress is the yield strength
divided by safety factor.
I.E : Carbon Steel Pipe below creep
range commonly has allowable stress
is 2/3* y or * u. For detail see
Table A-1 in B31.3

3. 2. Basic Stress Concepts

Stress due to axial force

= F/A

F = Axial force acting on cross section (kg)

A = Cross-sectional of pipe (mm2)

Stress due to bending and torsion

b = Mb / Z
t = Mt / 2Z

Mt

Mb = Bending moment (kg-mm)

Mt = Torsional moment (kg-mm)
Z = Section modulus of pipe (mm3)

Mb

Stress due to internal pressure

H = PDi / 2t (Hoop)

L = PDi / 4t (Longitudinal)
P = Design pressure (kg/mm2)
Di = Inner diameter (mm)
t = Thickness of pipe (mm)

3. 3. Thermal Effect

Thermal Expansion
= T x x L ; (mm)
Carbon Steel +/- 1 mm/m for 100oC
Stainless Steel +/- 1.35 mm/m for 100oC

(Pushed)

Thermal Stress
= x = /L x E
= T x x E

Reaction Force
F=xA

Damage

Example: 1meter length of 8 NPS CS Pipe STD at 100oC.

T ambient = 20oC
1. = (100-20)x12x10-6x1000 = 0.96 mm
2. = (100-20)x12x10-6x20000 = 19.2 kg/mm2
3. F = 19.2 x x (2192-2032)/4 = 27.6 ton

Force

4. Pipe Support

Sliding Support

Control Valve
Tight Support

4.1. Support Around Control Valve

Variable Spring Support

Adjustable Guide

4.2. Spring and Adjustable Support

Pad
Shoe

Sliding Plate

4.3. Hold Down Guide

4.4. Anchor

Structure
Eye Bolt

Spring Hanger
Turnbuckle

Pipe Clamp

4.5. Spring Hanger Assembly

4.6. Stopper

5. Applicable Codes

5.1. Piping Design Code

ASME B31.1 Power Piping

ASME B31.3 Process Piping
ASME B31.4 Pipeline (Hydrocarbon)
ASME B31.8 Pipeline (Gas)
ASME Section III Nuclear Component
Design

ASME: The American Society of Mechanical Engineers

API: American Petroleum Institute
NEMA: National Electrical Manufacturers Association
WRC: Welding Research Council

5.2. Related Code for Nozzle

Evaluation

API Std 610 Centrifugal Pump

API Std 611 Steam Turbines
API Std 617 Centrifugal Compressor
API Std 618 Reciprocating Compressor
API Std 650 Welded Steel Tanks
API Std 560 Fired Heaters (Furnace)
API STD 661 Air-Cooled Heat Exchangers
(AFC)
NEMA SM23 Steam Turbines
ASME SEC VIII Pressure Vessel
WRC 107, WRC 297 Local Stress on
Nozzles

6. Pipe Stress Analysis using Caesar II 4.50

6.1. Required Data:

Piping Configuration complete with

dimension.

Material Spec. :Size, Thickness,

Material Properties, method of
bracing, etc.

LDT (Line Designation Table):

Pressure, Temperature, Insulation
Thickness, Density etc.

Equipment Drawing to determine

nozzle movement.

Wind and earthquake loading.

Standard valve and flange weight.

Number of operating cycles if any.

Misc. item drawing such as

silencer etc.

Spring Support
Vertical Guide

Spring Hanger (Typ. 12ea)

V-1002
Trunnion (Typ. 3ea)

V-1001
Guide (Typ. 3ea)

K-3301C
K-3301B
K-3301A

6.2. Item need to be concerned:

Boundary Condition.

Operating Case, i.e: pump, run or

stand-by.

Friction.

7. Code Compliances and Nozzle Evaluation

7.1 Primary vs. Secondary Loads

Primary Load Characteristics:

Secondary Load Characteristics:

1.

1.

2.
3.
4.

5.

Primary loads are usually force

driven (gravity, pressure, spring
force, relief valve, fluid hammer etc).
Primary loads are not self-limiting.
Primary Loads are typically not
cyclic in nature.
Allowable limits for primary stress
are related to the material yield
stress, the ultimate strength or
time-dependent stress rupture due
to sustained load.
Excessive load causes plastic
deformation and rupture.

2.
3.
4.

5.

Secondary loads are usually

displacement driven (thermal exp, anchor
movement, settlement, vibration etc).
Secondary loads are almost self-limiting.
Secondary Loads are typically cyclic in
nature except settlement.
Allowable limits for secondary stress are
based upon cyclic and fatigue failure
modes.
A single application of load never
produce failure.

7.2. Code Stress Equations

7.2.1. B31.1 Power Piping

S sus

0.75iM A Pd o

SH
Z
4t

S EXP

iM C
S A f (1.25SC 1.25S H S SUS )
Z

SOCC

0.75iM A 0.75iM B Pd o

kS H
Z
Z
4t

7.2.2. B31.3 Process Piping

S sus

Fax [(ii M i ) 2 (io M o ) 2 ]1/ 2 Pd o

SH
Am
Z
4t
2

S EXP

[(ii M i* ) 2 (io M o* ) 2 4M T ]1/ 2

S A f (1.25SC 1.25S H S SUS )
Z

SOCC S SUS Sl 1.33S H

Where:

Where:

MA = Resultant moment due to sustained, kg-mm

Fax= Axial force due to sustained, kg

SH = Allowable stress at operating temperature, kg/mm 2

Mi = In-plane bending moment due to sustained, kg-mm

Mo = Out-plane bending moment due to sustained, kg-mm
Mi* = Range of in-plane bending moment due to expansion, kg-mm
Mo* = Range of out-plane bending moment due to expansion, kg-mm
SH = Allowable stress at operating temperature, kg/mm 2
ii ,io = In-plane, out-plane intensification factor
MT = Torsional moment due to expansion, kg-mm
SA = Allowable expansion stress, kg/mm 2
SC = Allowable stress at installation temperature, kg/mm 2
Sl = Bending stress due to occasional loads such as wind/earthquake
f = Stress range reduction factor

= Intensification factor

Mc = Resultant moment due to expansion, kg-mm

SA = Allowable expansion stress, kg/mm2
MB = Resultant moment due to occasional, kg-mm
k

= occasional factor
= 1.2 for loads occurring less than 1% of the time
= 1.15 for loads occurring less than 10% of the time

SC = Allowable stress at installation temperature, kg/mm2

7.2.3. B31.4 Liquid Transportation Piping

7.2.4. B31.8 Gas Transportation Piping

S sus Slp Sb 0.75 x 0.72 x SYield

S sus S lp S b 0.75 S x F x T
2

S EXP ( Sb* 4St )1/ 2 0.72SYield

S EXP ( Sb* 4St )1/ 2 0.72S

SOPE F EaT v S H S EXP S SUS (1 F ) 0.9 SYield

S OPE S EXP S SUS S

S OCC Slp Sb** 0.75 x 0.72 x k x SYield

S OCC Slp Sb** 0.75 x S x F x T x k

Where:
Slp = Longitudinal pressure stress, kg/mm 2
Sb = Bending stress due to sustained, kg/mm2
Sb* = Range of bending stress due to expansion, kg/mm 2
St = Range of torsional stress due to expansion, kg/mm 2
Sb** = Bending stress due occasional, kg/mm 2
Syield = Specified minimum yield stress material, kg/mm 2
F

= 1 (under ground pipeline); 0 (above ground pipeline)

= Modulus of Elasticity

= Thermal expansion coefficient

T = Temperature change of pipe from ambient

v

= Poissons ratio

SH = Hoop stress kg/mm2

k = Occasional load factor

Where:
Slp = Longitudinal pressure stress, kg/mm 2
Sb = Bending stress due to sustained, kg/mm 2
Sb* = Range of bending stress due to expansion, kg/mm 2
St = Range of torsional stress due to expansion, kg/mm 2
Sb** = Bending stress due occasional, kg/mm 2
S = Specified minimum yield stress material, kg/mm 2
F

= Construction type

T = Temperature derating factor

k = Occasional load factor

7.3. Nozzle Evaluation

7.3.1. Pump (API Std 610)

7.3.2. AFC (API Std 661)

7.3.3. Pressure Vessel/Heat Exchanger (KBR Specification)

Note: For detail see Halliburton KBR

Specification Doc. No: 308-7080-ST-54-101

7.3.4. Furnace (API Std 560)

7.3.5. Compressor and Turbines (NEMA SM23)

3FR M R 500 De

Individual Forces and Moments

Fx = 50 Dc

Mx = 250 Dc

Fy = 125 Dc

My = 125 Dc

Fz = 100 Dc

Mz = 125 Dc

Total Resultant Forces and Moments

3FR M R 500 De

3FR M R 500 De
Combine Loads for Inlet and Outlet

2 FC M C 250 DC

7.3.6. Tanks (API Std 650)

Note:
Appendix P on API Std 650 shown that the nomogram is
only applicable for tanks larger than 36 m in diameter.
If not we will use WRC297 to verify our piping loads are
within allowable or not , but it will be better to ask Tank
Department to verify our piping loads.
API Std 650 is not mention how to verify the nozzle loads at
roof of tank.

8. Designer Responsibilities Related to Stress Analysis Work

To prepare stress sketch/isometric drawing based on critical line

list from stress engineer.
To prepare piping loading information for Civil and Equipment
Department and Stress Engineer shall indicate the loads.
To utilize the span table for horizontal support (guide) and
vertical support (resting).
To select a proper pipe support based on pipe support selection
criteria and stress sketch from stress engineer.
To inform the clearance for spring support installation.
To prepare misc. support drawing as needed and then shall be
verified by Stress Engineer.
Etc.

8.1. Piping Loading Information to Equipment

Plan View

8.2. Around Pump

Items to be concerned:

Adjustable Support

1.

Shortest suction line shall be planned to

minimize pressure loss.

2.

Adjustable supports shall be installed for

suction and discharge line for pump
maintenance and alignment and the
location as close as possible to the
nozzle.

3.

Care shall be taken in thermal stress

calculations because the entire piping
does not always have the same
temperature, depend on operation plan.

4.

To relieve reaction force and moment

due to thermal stress on the piping,
expansion loops and restraint supports
such as anchor, stopper, guide, resting
and spring support shall be used.

8.3. Around Reactor and Fired Heater

Reactor

Constant Hanger
Lift Off

Constant Hanger

Sway Brace
Items to be concerned:
1.

Piping shall be designed to have

sufficient flexibility but it shall be
arranged as short as possible.

2.

Piping support around reactor shall be

selected to eliminate the vibration and
excessive forces and moments to the
reactor nozzle due to thermal stress.
Fixed type support shall be installed as
close as possible from the nozzle.

3.

Sway brace is vibration eliminator and

identical to variable hanger in their
resistance against thermal expansion, so
should be installed at location where the
thermal displacement is as smaller as
possible.

Sway Brace

Adjustable Guide
Fired Heater

8.4. Around Compressor

Items to be concerned:
Re-strut
Re-strut

1.

Piping route shall be flexible to prevent

excessive forces and moments on the
compressor nozzle.

2.

Piping support shall be installed well

balanced so no excessive forces and
moments on the compressor nozzle.

3.

Piping connected to and from suction

and discharge of compressor shall be
equipped with vibration proof as
required.

4.

Vibration proof piping support shall

allows piping movement caused by
thermal expansion and prevent piping
vibration caused by compressor.

5.

Sleeper support shall be adopted to

abate the vibration of piping and shall
be not connected or closed to
compressor shelter to prevent sleeper
piping vibration is transmitted to
shelter.

6.

To check the natural frequency of

piping system against compressor.

7.

Expansion joint shall not be used for

vibrating line which may cause
damage.

Compressor
Compressor

Adjustable
Guide
Adjustable
Guide

Vessel

Re-strut

8.5. Around AFC

Items to be concerned:
1.

Support arrangement of piping

manifold shall be prepared to make it
simple and economic.

2.

Piping route shall be flexible to prevent

excessive forces and moments on the
AFC nozzle.

3.

Piping support around AFC shall be

selected to eliminate the vibration and
excessive forces and moments to the
AFC nozzle due to thermal stress.
Stopper type support shall be installed
as close as possible from the center of
piping manifold.

4.

Vibration due to slug force can be

eliminated by install properly stopper
and guide support.

AFC

Stopper

Vessel

THE END