ISSUE NO.

99-01

October 23, 2006

What is Piping Stress Analysis?

Piping Stress analysis is the process of evaluating the structural integrity of a given piping system within the guidelines established by applicable codes and standards of the particular industry. The objective of piping flexibility and stress analysis is to ensure safety against: failure of the piping material or anchor structure from overstress leakage at joints overloads at connected equipment PIPE SPAN CHART
(Guideline 000.250.2040, Attachment 04)

Stress Computer Software

Fluors licensed piping stress computer program is AutoPipe. It is a TOOL used by the stress engineers in the analysis of piping systems based on data such as design conditions (temperature, pressure), climatic conditions (solar, wind, earthquake), pipe sizes and materials, commodity, supports and support locations, equipment data, allowable stresses. AutoPipe incorporates many of the limitations placed on piping systems and the attached equipment. The limits are specified by engineering bodies such as ASME (American Society of Mechanical Engineers) codes, API standards (American Petroleum Institute), NEMA (National Electrical Manufacturers Association, Inc.), etc.

When using the pipe span chart, allowance must be made for deviations from the conditions given on the chart. In special cases (such as special pipe materials like plastic pipes), see stress engineer for allowable span information. Approved vendor catalogs may be used if available.

Flexible and Stiff Piping

The figure below shows the examples of stiff and flexible piping. When piping is subjected to change in temperature and if the pipe is not restrained from expansion, no stresses are developed and the pipe just expands or contracts. When the pipe is restrained, stresses and forces of considerable magnitude are created.

that the general formula for thermal expansion is

= eL
Where: e=linear thermal expansion which varies with material type and temperature (Reference 000.250.9823, ASME codes) L=original pipe length =Greek letter Delta representing change in length Sample calculation: 6-CS pipe @ T=350F e=0.0226 in/ft, L=100 ft = eL = (0.0226)(100) = 2.26 inches

ISSUE NO. 99-02

October 23, 2006

What is a Stress Log or a Flex Log?

Piping Stress Log or Flexibility Log is the list of Piping systems that is created by the Piping stress Engineer to identify piping systems that would require stress analysis (Guideline 000.250.2250). It helps the designer to identify the systems requiring stress analysis. It also indicates the status of the system.
Pick-ups. Pick-ups can be considered if pipe span are not met but the designer should be aware of the conditions of both the line to be pickedup and the line picking up because it may act as restraint on either of the lines. The designer should also consider if its thermal expansion would be in the same or opposite direction. It should be noted that piping systems with temperatures more than 200F are not recommended for pick ups. Loads caused by the pickedup lines on stress required systems should also be included on pipe stress sketches. Any extra loads should be covered in the stress analysis.

What is a Slug flow?

Slug flow is a condition created by a sudden flow of high velocity gas over the surface of a slowly moving liquid in the pipe. This produces a liquid wave which can become a slug if it crests at the top of the pipe. The impact of this liquid slug, moving at the velocity of a blowdown gas, generates tremendous force when exerted on an elbow. Process and Control systems Engineers are the ones who determine slug flow. For piping systems with slug flow, all changes of pipe run direction shall require restraints. Standard guides and anchor are normally inadequate for restraining slug flow. Special design is required. Structural T supports are usually tall and tend to offer little resistance to horizontal loads. Formulas for the calculation of slug force that would be acting on every bend can be found in Guideline 000.250.1203.

When do piping systems require 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. Fluor standards state that straight pipes producing expansion growth of more than 12 inches require stress loops (Guideline 000.250.2232). anchor

that for uniform load in a simply supported span, the formula for load calculation is W = wl W

If 1+2 > 12, then a loop is required. See figure below.

W 2

W 2

Where: W= Total weight between supports (lbs) W= weight per foot of pipe (include water for test loads and include commodity and insulation for operating loads). Reference 000.250.9822 l= Distance between supports (in feet)
.

ISSUE NO. 99-03

October 23, 2006

Codes and Standards Related to Piping

ASME American Society of Mechanical Engineers: ASME B31.1 - Power Piping, includes all piping system for electric generating plants, industrial and institutional plants, central and district heating plants ASME B31.3 Process Piping, includes piping within the property limits of facilities engaged in the processing or handling of chemical or petroleum or related products ASME B31.4 - Liquid Petroleum Transportation Piping, includes piping transporting liquid petroleum in petroleum products between producers facilities and delivery and receiving points ASME B31.8 - Gas Transmission and Distribution Piping, includes gas transmission pipelines, gas compressor stations ASME Section VIII, Divisions 1 and 2 - Pressure vessels API American Petroleum Industry: API 661 - Air-cooled heat exchangers for general refinery services API 610 - Centrifugal pumps for general refinery services API 611 - General purpose steam turbine for refinery services API 617 - Centrifugal compressors for general refinery services API 618 - Reciprocating compressors for general refinery services API 650 - Welded steel tanks for oil storage NEMA National Electrical Manufacturers Association SM-23 Steam Turbines for mechanical drive service

Hanger rods Hanger rods are used to support lines from above if it is not possible to support the line from the bottom of the pipe. More often than not, hanger rods require the approval of a stress engineer. In choosing hanger rods, support clearance is being considered between the pipe to be supported and the structure that the hanger rod is to be attached.

What are Rigid Struts?

Struts are rigid rods of adjustable length. They are similar to rod hangers except that they are attached to the pipe and to the structure by means of lubricated guides which allow motion in a single plane. Thus, limited movement of the pipe within the angular displacement of the struts is allowed for without resistance. Any movement, however, in the axial direction of the strut is suppressed. Rigid struts can take on several important functions such as: absorption of shocks In the event of unscheduled loads; guiding of piping systems to enforced planned thermal displacement; stabilizing of flexible piping system by providing so-called zero positions; construction of flexible fixed points, primarily in vertical riser pipes.

.that the American Petroleum Institute (API) was established in 1919 as the first National Trade Association in the United States to encompass all branches of the petroleum industry. This organization has produced numerous standards applicable to all sectors of the petroleum industry, from the drilling of oil wells to the storage and distribution of an end product. Piping specifications published by API are the recognized standards in the oil industry.

ISSUE NO. 99-04

October 23, 2006

How are piping systems classified by stress?

A. Critical Service Piping Systems
1. 2. 3. 4. 5. Pump, turbine, blower, and compressor piping Piping designed for 500 F or greater. Piping designed for 1000 psig or greater. Piping greater than 24 inches diameter. Piping connected to sensitive equipment, such as fired heaters, fin-fan coolers, reactors and boilers. 6. Piping supported or guided from stress-relieved vessel. 7. Jacketed piping. Pre-Engineered Supports Pre-engineered supports are supports such as base supports, rod hangers, shoes, guides and anchors as shown in the detail practices listed in Specification 000.250.4200: Table of contents: Piping Support Elements - Fabrication Details.

By computer

analysis

B. Intermediate Service Piping Systems

1. 2. 3. 4. 5. 6. Piping designed for 250 to 499 F. Piping designed for 500 to 999 psig. Piping from 6 in. to 24 in.. diameter. Nonmetallic piping. Vacuum lines. Pipeway and yard piping.

By manual calculations

C. Mild Service Piping Systems

1. Other piping not indicated in Critical and Intermediate Piping Systems.
By visual inspection

What are the basic loads considered by the stress engineer?

1. Primary Load (Sustained Load) Refers to the type of load that remains constant throughout the operating life of a piping system. This includes the dead weight of the pipe, valves, insulation, flanges, snow, other mechanical loads, and the live load represented by the flowing commodity in the pipe. 2. Secondary Load (Thermal Load) Refers to the type of load that goes through a cycle as the piping system heats up and cools down in its normal course of operation. Loads due to thermal expansion, anchor or structural movements due to wind or seismic, tank or equipment settlement are secondary loads. 3. Occasional Loads Refers to the type of load caused by wind, seismic, psv discharge, water hammer, and slug flow effects. Pressure waves due to weapons blast effects are also considered occasional in nature.

.that Engineered supports such as spring hangers, spring can base supports, snubbers, rigid struts and constant support spring hangers are designed by Stress Engineers for a specific purpose and location. The Piping Designer should inform the stress engineer for any changes made to piping design.

ISSUE NO. 99-05

October 23, 2006

Design & Analysis of Cold Piping

The problems encountered in the design & stress analysis of cold piping system are no different from less exotic fluids. Piping movement for cold piping are contractions not expansions. These will affect the method of supporting and anchoring the pipe. The supports should be placed so that there will be a minimum of heat gain by the fluid in the pipe. Wood or molded rigid polyurethane foam is placed between the pipe support shoe and the steel or concrete. Stress Engineers should coordinate with the Cold Box vendor with regards to allowable loads on pipes terminating on the cold box nozzle. If allowable loads are not available, submit loads to vendor or analyze the system to include piping and equipment inside the cold box if available.

What is Cryogenic?
Cryogenics is the science of cold being derived from the Greek word kryos meaning icy cold. A cryogenic process utilizes low temperature to produce a physical change in liquid, solid or gas such as to liquefy gases such as oxygen, nitrogen and helium Some examples of cryogenic fluids:: Boiling Point Freezing Point Acetylene (C2H2) -114 oF -119 oF o Ethane (C2H6) -127.5 F -277.6oF o Nitrogen ( N2 ) -320.5 F -345.8oF

What is the difference between low temp service and a cryogenic service?
The arbitrary design temperature separating a low temp service and a cryogenic service: Design Temperature (oF) Cryogenic Service -425 to 151 Low Temp Service - 150 to 32

What is a cold box?

There are two ways to insulate a cryogenic plant. One method consist of applying insulation to each piece of equipment separately (this can be relatively expensive). A second method involves placing all the individual pieces as closely as possible, building a cold box around them and filling the voids with insulation. A cold box requires an insulation that can be packed into spaces between heat exchangers, drums, towers, valves and lines

Piping Material
Corrosion is not usually the factor in material selection. The decrease in ductility at about 50oF for plain carbon steel requires special carbon steels for use at low temperature. The ductility transition temperature is that temperature below which brittle fracture may take place. The following materials are generally used:

that a fraction of exposed square inch of uninsulated cryogenic pipe can produce a massive block of ice enough to interfere and hinder engineered items to function properly as designed.

Design Temp.
Cryogenic Low Temp -425 -320 -150 -75 -50 -20 5 to 321 to 151 to 76 to 51 to 21 to 4 to 32

Matl
S.S. 9 Nickel 3 Nickel 2 Nickel C. S. C.S. C.S.

Pipe (ASTM Matl)

A 312-304.304l,316.316l A 333-8 A 333-3 A 333-3 A 333-6 A 333-1 or 6 A 53-B, A106-B
References: Piping Handbook

Crocker & King Pressure Vessel Handbk Bednar H.H.

ISSUE NO. 99-06

October 23, 2006

Pipe Stress Sketch Checklist:

Stress Sketch Tips

1. 2. 3. 4. Be neat with your sketch. Follow sketch examples and show values in parenthesis (x-x) below line. In manual sketches, do not use dimension lines. For dimensions, use centerline of fitting to centerline of fitting, centerline of supports to centerline of branch, face of flange to centerline of fitting, etc. Be careful when dealing with elevations that are based on top of steel or bottom of pipe. Round dimensions to nearest inch. Give only pertinent information. Do not duplicate information like line numbers and elevations. Do not show the global coordinate symbol. Call out reducing branch fittings. Show nozzle size and ratings. Manual stress sketches-Fill in appropriate title box information. Show material type and schedule. Manual sketches-Show north arrow up and to the right. Use correct orientation for your configuration. Do not put more than one line number on a stress sketch. Line conditions could be different. Exception would be a system sketch requested by stress. Call out supports.

Is configuration current? Have all branches and applicable fittings been shown. Show line size and flow direction. Check sketch against P&ID. Has equipment been identified?
Nozzle number (vendor drawing) Size and rating (vendor drawing) Orientation and location (vendor drawing) Anchor point for exchangers (location control plan)

Have all hard supports been identified/located? Show operating and design conditions. Note the following conditions:
Steam out Vacuum Regeneration Start up Upset Pulsating flow Slug flow

5. 6. 7. 8. 9. 10. 11. 12. 13.

Insulation and tracing requirements noted. Is revision number current (note 1) Has flexibility log been updated

14.

Note 1: If sketch is being revised, revised items must be identified with a cloud and revision triangle. Revision number will be increased. Flexibility log must be updated to reflect current revision number and date.

ISSUE NO. 2000-07

October 23, 20060

Understanding stress comments & symbols on pipe stress sketches

The Coordinate axis This symbol is important in helping the stress engineer in determining where the north of the piping configuration is. This also is used to determine in which axis the allowable loads would be compared to. File Name The File name is used to represent one complete piping system which might compose of several line numbers terminating on a FN : 3105 nozzle or an anchor. The File name is important for filing whether electronic or hardcopy and would help stress engineers and piping designers to easily find files for reference. This is usually named by the main line on the system. Nodes Nodes are symbols which represents pipe elements on AutoPipe 10 50 software. The node numbers will be changing if the model is modified and ask for numbering, the pipe segment name stay same This is where the stress engineer would base his notes in conveying his instructions to the designer. Piping Notes PIPING The Piping Notes gives complete and Add guide @ node 150 with gap = 1 inch clear instructions to the piping Use adjustable base support @ node 60 designer on what to add or remove to Delete support @ node 180 a system or how it would be rerouted Add spring hanger @ node 50 to attain client requirements and Extend pipe from node 30 to 40 by 1 foot. code allowable based on the result of Reroute piping as shown from node 100 to 170 the stress analysis. Structural Notes The structural notes inform the piping designer and the STRUCTURAL structural group on loads that are significant which would be Fy = - 1.2 kips (OPE) considered in calculating structural beams and members. Fy = - 3.6 kips (HYD) The stress engineer would consider the worse condition and Fx = + 2.5 kips (OPE) load the system would experience during his analysis. Fz = + 1.0 kips (OPE) The structural note, not only indicate downward loads but also Fy = - 3.0 kips (HYD) loads for guides and anchors which would depend on whatever the coordinate axis is. Loads less than 0.5 kip (500 lbs.) are not noted. 5 Movements on Pipe Movements on pipe are usually significant movements that piping designers should watch out for and consider during its operating 3 condition. They are usually movements more than one inch and are shown with node numbers and are placed near the node. It is usually used with direction or by using the sign convention based on the coordinate axis. Miscellaneous Notes: C.A. = 0.063 Corrosion Allowance of pipe based on specs Specific Gravity of commodity from process group SP. GR. = 0.8 Used by stress engineers in analyzing the system.

The Initial Thermal displacement The initial thermal displacement of the equipment is acquired through the Equipment Thermal Profile. This tells us how the equipment would expand or contract when the worst thermal condition is applied. This is usually placed near the nozzle of the equipment in a stress sketch.
DX = 0 in. DY = -0.025 in. DZ = 0 in.

Stress Stamp, Signature and Revision No. This is very important to the stress sketch because it shows that the system was analyzed and checked by the stress engineer before it could be released to design. This includes the date received, Stress Engineers Initials, Checkers Initial, Date Issued to design and Revision No. Received date: 11/9/99 Stress Engr : DNonog Checked by : ALim Issued date:: 11/12/99

ISSUE NO. 99-08

October 23, 20060

Squad checking Engineered Items

BASE SRINGS AND SPRING HANGERS

Shown above are two different spring hangers. Note that the constant spring on the left requires space because of its shape. Check if there would not have any clashes with adjacent pipes or structure. The spring on the right is a common spring support configuration dropping down from columns. It should be noted that the lug elevation on the pipe is different from the structure member elevation which will be given to the equipment group.

Squad checking for spring supports is very important in giving the vendor pertinent information he needs to give us the right model and type and also to avoid confusion and miscommunication between the vendor and the piping design.

Notations
A. Check the view as shown with respect to the Plant North, South, West, or East. B. Check the location/orientation of the spring scale. Check on the arrangement drawing and piping layout if the scale can be read or accessed from grade or nearby platform. C. Check that the minimum specified clearance is available. Erase the minimum length given by the stress engineer (for reference) and put the actual dimension. Dimension shall be to the nearest 16th of an inch. If the minimum clearance can not be met inform the concerned stress engineer immediately. D. Indicate the actual Reference drawing number. The reference drawing number indicated by the stress Engineer comes from the stress isometric drawing or sketch. E. Tag assembly on the specified node number on the pipe stress sketch should be indicated on the final isometric drawing. F. Check the Service Temperature and Insulation thickness from the latest revision of line list and P&ID. G. Indicate B.O.S. El. or T.O.S. El. of supporting structural member for spring hangers H. Submit the maximum load to the Structure group for the sizing of their structural members.

Above is a sample standard form to be filled out by the pipe stress engineer and to be squad checked by the designer and the structural group before it could be used for Technical Bid Analysis or direct order and purchase.

Above is a common Base Spring support. Note that actual spring dimension could easily be acquired by the stress engineer from vendor catalogs. Inform stress engineer if space is not be possible.

ISSUE NO. 00-09

October 23, 2006

SPRING SUPPORTS
Spring Hangers and Supports are vertically moving components used to compensate height displacements of piping due to thermal expansion. Primarily springs are used to relieve loads on equipment nozzles. A spring will probably be Spring hangers are sized using operating conditions. Types are: Constant - spring will exert the same lifting effort as the pipe moves up or down and is used where vertical movement of the pipeline is so great that the maximum allowable variability cannot be met with a variable-load spring support. Variable - springs load carrying capacity varies considerably as the spring is compressed or extended from a fixed reference point and is used when it is necessary to carry only the working dead weight or load of a piping system while allowing the pipeline to move in both horizontal and vertical directions. The general criteria from most of the international standards is that the variation in supporting force between cold (installation) and hot (operating) position must not exceed 25% of the operating load. If variability percentages are below 12%, Consideration should be given to using the next lower spring scale, if exceeding 25%, the next higher spring scale must be used. If between the percentages mentioned, the highest percentage should be listed. Spring Variability is computed by the formula, % Variability = or = spring rate x required travel x 100% HL CL HL x 100% HL

required for top suction and discharge line when -Pump nozzle size is two or more sizes smaller than the line and valve sizes. -Pump nozzle is the same size as the line and valve ratings or 300# or more.

That the allowable vertical angulation of the spring assembly for spring hangers range from 4 to 6 degrees. This angle should be computed from the lowest pin to the highest pin in the assembly.

where:
Variability - the variation in supporting a given amount of displacement. This is the principal consideration in the selection of variable spring. spring rate - is the stiffness in force per unit displacement travel - deflection, variation of the pipes vertical position CL - cold load, the deadweight that is carried by the spring after installation HL - hot load, when system is in operation and the spring support is altered from its cold loaded position

Reference: Lisega Product chart