Mechanical Design Process

• Scope : Structural Steel and Piping Stress Analysis + Pipe Support Design

• Structural Steel : HRSG Platform and Silencer Support Steel

• Piping Stress Analysis + Pipe Support Design

• Interconnecting Pipe : Pipe Stress Analysis + Pipe Support Design
• External Pipe : Pipe Support Design
 Interconnecting Pipe Analysis
• Required Design Input :
• Item 9.01 Design criteria for piping and nozzles
• Item 9.72 External pipe list
• Item 9.78 Trim piping list
• GA drawings
• PPA drawings
• ASME calculation
• P&ID, PPD
• Item 6.11 Header support design data
 Interconnecting Piping Analysis
• Required Design Input (continue):
• Safety valve weight and force information
• Interconnecting pipe arrangement drawings
• Valves weight and length
• TS Estimate
• Item 5.02 Finned tubes ordering data
• Item 4.01 Header design summary
• Item 2.01 Summary MD Parameter
• Agreed hanger manufacturer
• Silencer allowable nozzle load
 Interconnecting Piping Analysis
• Design Process:
• Build piping geometry on “Pipeplus”. For the complex line, geometry may be
taken from solid edge.
• Define pipe properties
• Define material properties
• Define loading (operating temp. and design pressure)
• Define anchor point boundaries
• Define wind and seismic load
• Define other input data (weight, tee, sif etc.)
• Define code combination loads
• Define non-code combination loads if required
 Interconnecting Piping Analysis
• Design Process (continue):
• Determine pipe supports location and select appropriate support
• Verify all inputs are ok then run the program
• Check stress ratio
• Check allowable load on hanger and nozzle compare to anchor reaction
• Check movement
• Repeat the above mentioned steps for hydro test case
• If everything acceptable, prepare a selection sheet and pipe support load
summary
 Interconnecting Piping Analysis
• Design Process (continue):
• Compile all documents and check list for checking purpose by the checker
• Checker will check based on check list and make comments as required
• Designer will make correction based on checker comments
• When the documents is approved then submit to Windsor for review
• If Windsor agree with the analysis, pipe support drawing will be executed
 Pipe Support Design
• Design Input Required :
• Released pipe support selection sheet
• Piping analysis file
• Pipe arrangement or isometric drawings
• GA,PPA,Boiler casing, silencer support steel drawings
• Document 20.112 : Welded pipe attachment design standard
• Document 20.113 : Pipe support design standard
• Recommended steel shapes standard (AISC, European, JIS)
• Information of HRSG concrete slab if any
• Customer’s steel information
 Pipe Support Design
• Design Process :
• If 2D pipe arrangement drawing isn’t available, plot piping layout from isometric
to PPA drawing
• Plot pipe support location based on coordinates shown on model or isometric
drawing
• Determine welded attachment size based on Doc.20.112
• Plot welded attachment to drawing
• Select pipe support arrangement based on Doc.20.113
• Create pipe support sketch considering the nearest steel or available structure
around and interference with others
 Pipe Support Design
• Design Process :
• Pipe support sketch must be drawn in scale including the purchased hardwares
• Analysis as required for the additional steel structure. Consider maximum load
from operating or hydro test case
• Finalised pipe support drawing :
• Fill up bill of material
• Complete Piping information
• Add note and reference drawing
• Consider pipe support installation
• Consider weld size, shop/field weld
 Pipe Support Design
• Design Process :
• Finalised pipe support drawing :
• Reference to certain location
• Observe when piping in hot condition whether any hit or guide missing from the
stopper
• Observe if significant amount of load will effect other structure
• Observe any hit with other pipe support or possibility to combine 2 or more pipe
supports
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Software : new software (Autopipe) we never use before. Is pipeplus still
prefer for the future ?
• Current ESI piping analysis softwares :
• 2 seats Autopipe V6.2 (from Windsor)
• 1 seat Autopipe V6.3
• 3 seats Pipeplus V9.12
• 1 seat Caesar II V4.5
• Analysis file : on some files of Becancour projects can’t be run (may be using
different version?). Need analysis file that can be run, in case for example if
we want to
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Analysis file :….change quantity of spring hanger due to space limitation. So
far done manually.
• On pipeplus : hanger option is not available for PTC. ESI has added PTC
hanger data, Windsor wasn’t able to run.
• Pipe movement : on Becancour there is a summary for maximum movement.
Need agreement which movement will be put on drawing (operating case or
maximum movement)
 Pipe Analysis and Pipe
Support Design Lesson
• PipeLearn
movement :….in some cases found that movement is larger than
specified gap.
• Pipe guide gap : Current ESI understanding is gap specified on the drawing =
model gap + thermal expansion of lug & pipe.
• Metric unit :
• Confusing to specify plate thickness : for example
• Nubaria : t (mm) x w (mm) x l (mm)
• Becancour : t (inch) x w (mm) x l (mm)
Pipe Analysis and Pipe
Support Design Lesson
Learn
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Metric unit :
• Pipe diameter :
• Nubaria : DN 200
• Becancour : 8”
• Insulation thickness : no decimal required
• Rod diameter :
• Nubaria : mm
• Becancour : inch
• Steel shapes :
• Nubaria : L-100x100x10
• Becancour : L-4”x4”x3/8”
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Metric unit :
• Pipe diameter :
• Nubaria : DN 200
• Becancour : 8”
• Square tube :
• Nubaria : SHS 100x100x6
• Becancour : TS 4x4x1/4”
• Isometric drawing :
• Nubaria : pipe support location already shown
• Becancour : pipe support locations weren’t shown
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Pipe support location :
• Nubaria : follow isometric
• Becancour : follow model, found some pipe supports was close to nozzle. Need
back and forth communication to solve it.
• Coordinate :
• Found that coordinates shown on isometric drawings is incorrect. Need back and
forth communication to solve it.
• Anchor point :
• ESI follows Doc.20.105 to specify anchor points, it was not accepted by Windsor.
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Welded attachment weld size :
• ESI follows Doc. 20.112 mostly commented that weld is too large
• Pipe support configuration :
• Pipe support configuration as shown Doc. 20.113 was giving us idea how to layout
the support.
• Nozzle penetration assumption:
• Model it similar to main run with SIF on centre line and junction nozzle & main
run ?
• Insulation thickness:
• For vent pipes, insulation thickness is not clear enough which line will be
insulated. It will effect to pipe support design.
• Vent pipe:
• Not clear for design pressure and operating temperature. Item 17.01 showing
high inlet temp. but CS material was chosen.
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Combine pipe supports :
• Possible 2 parties working on different lines but actually the pipe support can be
combined if it is design only by 1 party.
• High energy drain :
• Not clear the definition of end point.
• Rework happen due to existing layout fail, need adding loops.
• Stress Intensification Factor : 2.1 or 1.3 for socked weld fitting ?
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Hanger for hydro test case :
• 2 different hangers were selected for operating and hydro case. Allow to increase
hanger allowable load @ cold ?
• Vertical stop :
• Coefficient of friction 0.1 on model means hanger rod ?
• Coefficient of friction 0.3 on model means support from bottom ?
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Interference problem :
• Pipe support vs nozzle
• Pipe support vs existing steel
• Pipe support vs valve
• Pipe support vs piping
• Pipe support vs bellows
• Pipe support attachment :
• Is it allowed to attached pipe support to drum ?
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Hanger orientation :
• Attaching hanger lug to allow pipe laterally move on 2 directions
• Pipe support vs platform steel :
• Use pipe support as main beam and platform steel attached to it for the
significant piping load.
• Valve cut sheet :
• Late valve cut sheets
 Pipe Analysis and Pipe
Support Design Lesson
Learn
• Concrete floor :
• Alstom piping run outside HRSG concrete slab
• Combine with the nearest pipe support/steel
• Incorrect weld symbol
• Missing bill of material
• Overlook customer specifiaction
• Corrosion allowance
• Pipe support distance requirement
• Pipe support attaching to main pipe
 Pipe Analysis and Pipe
Support Design Lesson
• NotLearn
knowing available shapes in the market
• Missing reference for support location