BASICS OF PIPE STRESS ANALYSIS

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Contents
Objectives of Pipe Stress Analysis Governing Codes and Standards Stresses in a Piping System Reducing Piping Stresses Basic Allowable Stress Loads on a Piping System Project Specifications and Guidelines
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Contents
Work Flow Diagram Stress Criticality & Analysis Method Piping Stress Analysis using Software Caesar II Type of Supports Questionnaire

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Objectives of Pipe Stress Analysis:

Structural Integrity:

Design adequacy for the pressure of the carrying fluid. Failure against various loading in the life cycle . Limiting stresses below code allowable.

Operational Integrity:

Limiting nozzle loads of the connected equipment within allowable values. Avoiding leakage at joints. Limiting sagging & displacement within allowable values.

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Objectives of Stress Pipe Analysis (Cont..):

Optimal Design: Avoiding excessive flexibility and also high loads on supporting structures. Aim towards an optimal design for both piping and structure.

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Governing Codes and Standards:

Codes and Standards specify minimum requirements for safe design and construction (i. e. provides material, design, fabrication, installation and inspection requirements.) Following are the codes and standards used for Refinery Piping: 1. ASME B31.3: Process piping Code 2. ASME B31.1: Power Piping Code 2. Centrifugal Pumps: API 610 3. Positive Displacement Pumps: API 676 4. Centrifugal Compressors: API 617

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Governing Codes and Standards (Cont..):

5. Reciprocating Compressors: API 618 6. Steam Turbines: NEMA SM23/ API 612 7. Air Cooled Heat Exchanger: API 661 8. Fired Heaters: API 560 9. Flat Bottom Welded Storage Tanks: API 650 10. Heat Exchangers: TEMA/ Vendor Specific/ 3PS-ME001. 11. Vessel/Column: 3PS-MV001/ Vendor Specific

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Stresses in a Piping System:

Sources for generation of stress in a Piping System: 1. Weight 2. Internal/External Pressure 3. Temperature change 4. Occasional Loads due to wind, seismic disturbances, PSV discharge etc. 5. Forces due to Vibration.
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Stresses in a Piping System (Cont..):

Sustained Stresses are the stresses generated by sustained loads. (e.g. Pressure , Weight). These loads are present continuously throughout plant life. Resistive force arising out of sustained stresses balance the external forces keeping the system in equilibrium. Exceeding sustain allowable stress value causes catastrophic failure of the system. As per ASME B 31.3, (clause 302.3.5) The sum of the longitudinal stresses, SL, in any component in a piping system, due to sustained loads such as pressure and weight, shall not exceed the product Sh xW Where, Sh=Basic allowable stress at maximum metal temperature expected during the displacement cycle and W=weld joint strength reduction factor.

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Stresses in a Piping System (Cont..)

Pressure Stresses are taken care of by calculating and selecting proper pipe thickness. The pressure thickness (t) of a straight pipe can be obtained as per ASME B31.3 from the following equation (Clause 304.1.2): P=internal design pressure D=OD of pipe S=Allowable Stress E=Weld Quality factor Y=Factor from code W=weld joint strength reduction factor c= sum of mechanical allowances, corrosion, erosion etc. Min. reqd. thickness, tm= t+c Min. reqd. nominal pipe thickness= tm/(1-0.125) or tm+a where .125(12.5%)= mill tolerance for seamless pipes per ASTM std. a= mill tolerance in mm for other pipes per ASTM std. This thickness to be rounded off to the next higher schedule.

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Stresses in a Piping System (Cont..):

Change in length of a pipe of length L due to temp change (T) is given by

L=L T

Here, =Co efficient of thermal expansion = change in length of unit length element due to unit change in temp. Two values in Code (Table C1 and C3 in ASME B31.3 Appendix C):

Table C1 denotes total linear thermal expansion between 700 F to Indicated temp (unit=in/100ft). Table C3 denotes mean coefficient of linear thermal expansion between 700 F to indicated temp (in/in/0F).

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Stresses in a Piping System (Cont..):

Expansion stresses are generated when the free thermal growth due to temperature change is restricted. These are self limiting or relenting. SIF( Stress Intensification Factor) This is the ratio of the maximum stress intensity to the nominal Stress. SIF factors for different components can be obtained from Appendix D of ASME B31.3.

Displacement Stress Range due to thermal expansion is calculated based on eqn SE = ( Sb2+4St2)1/2 per eqn 17 from ASME B31.3( clause 319.4.4) This SE value shall not exceed SA value where SA= Allowable Displacement Stress Range

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Stresses in a Piping System (Cont..):

As per ASME code B 31.3 (Clause 302.3.5) the allowable displacement stress range (SA) can be given by the following equation: Here, f= Stress range reduction factor Sc=basic allowable stress at minimum metal temp

When Sh > SL , the allowable stress range is calculated by the following equation:

SL=Longitudinal Stress due to sustained loads.

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Stresses in a Piping System (Cont..):

Occasional Stresses are generated by the occasional loads such as Wind, seismic, PSV discharge etc. This loads act in a piping system for very small period of time, usually less than 10% of total working period. As per ASME B31.3 clause 302.3.6 The sum of the longitudinal stresses, SL, due to sustained loads, such as pressure and weight, and of the stresses produced by occasional loads, such as wind or earthquake should be 1.33 times the basic allowable stress, Sh

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Stresses in a Piping System (Cont..):

Code does not explicitly explain the stresses generated due to vibration. The vibration problems are solved by engineering judgment and experience.

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Reducing Piping stresses:

Supports for Weight Flexibility for thermal loading Eg. Expansion Loops.

Flexibility check (as per clause 319.4.1, ASME B 31.3)

D=Outside Diameter of Pipe; y=Resultant of total displacement strains; L=developed length of piping between anchors; U=Anchor distance, straight line between anchors; Ea=modulus of elasticity at 210 C.

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Basic Allowable Stress:

Minimum of (As per ASME B 31.3) 1. 1/3rd of Ultimate Tensile Strength (UTS) of Material at operating temp. 2. 1/3rd of UTS of material at room temp. 3. 2/3rd of Yield Tensile Strength (YTS) of material at operating temp. 4. 2/3rd of YTS of material at room temp. 5. 100% of average stress for a creep rate of 0.01% per 1000 hr. 6. For structural grade materials basic allowable stress=0.92 times the lowest value obtained from 1 through 5 above.
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Loads on a Piping System:

Static Loads
Weight & Pressure Hydro test Thermal Expansion Settlement

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Loads On Piping System (Cont..):

Dynamic loads
Seismic Wind PSV, Slug Flow, Water Hammer Vibration

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Project Specifications & Guidelines:

3PS-PL-001: Piping Material Classes. 3PS-PL-003: Piping Design and Plant Layout. 3PS-PL-008: Piping Stress Analysis. 3PS-PL-009: Piping Stress Critical Line List. 3PS-PL-015: Pipe Supports. 3PS-PL-019: Pipe Support Standards. PE-PL-093: Stress Analysis Work Procedure.
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Work Flow Diagram:

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Stress Criticality & Analysis Method:

Highly Critical Lines (C1) (Steam turbine, Compressor connected pipelines) Moderately Critical Lines (C2) (AFC connected lines) Low critical Lines (C3) Non Critical Lines

By Computer Analysis

Visual/Computer Analysis By Visual Inspection

The above Criticality definition is based on project Spec. 3PS-PL-009

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Stress Analysis using Caesar II :

Inputs:

Stress Isometric from Layout Group LDT And P&ID from Process Equipment GA and Other detailed drawings from Mechanical Process flow diagram/datasheet if required from process Piping Material Specification PSV/ Control Valve GA and Datasheet from Instrumentation
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Stress Analysis using Caesar II (Cont..) :

Inputs (Cont..):

Soil Characteristics from civil for underground analysis Nozzle load limiting Standards Plot Plan for finding HPP elevation and equipment orientation. Governing Code

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Stress Analysis using Caesar II (Cont..):

Analysis:

Checking the completeness of the piping system received as a stress package. Node numbering on stress Iso. Filling the design parameters (Design temp, pressure, Ope. Temp, Min. Temp, Fluid density, Material, Line Size and thickness, Insulation thk and density, Corrosion allowance etc) on stress Iso. Modeling the piping system in Caesar using parameters from stress Iso. Analyzing the system and obtaining results.
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Stress Analysis using Caesar II (Cont..):

Analysis (Cont..):

Conclusion & Recommendation : Whether to accept the system or to suggest necessary changes in layout and supporting to make the system acceptable as per standard requirements.

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Stress Analysis using Caesar II (Cont..):

Caesar Spreadsheet Items as modeled in Caesar II Load Cases for Analysis

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Stress Analysis using Caesar II (Cont..):

Output:

Final marked up Isos to Layout Support Loads to Civil Spring Hanger Datasheets. Datasheets for Special Supports like Sway brace, Struts, Snubbers etc. SPS drawings Stress Package final documentation for records.
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Type of Supports:
Rest Guide Line Stop Anchor Variable Spring Hanger Spring Hanger Constant Spring Hanger Rigid Hanger Struts Snubbers Sway Braces

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Questionnaire:

What are the various types of loads which cause stresses in the piping system? Which code do we refer for Refinery Piping? Which standard governs the design of Pumps? The coefficient of thermal expansion of a substance is 1.8 mm/m/Deg.F. What is its value in mm/mm/Deg.C.? Which design specification do we follow to determine the criticality of a piping system? Calculate the minimum pipe thickness of a seamless 10 NB A106Gr B material with design pressure of 20 bars. (Design Temp= 3500C and Corrosion allowance= 1.6mm)?

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Questionnaire (Cont..):

For a 10 NB pipe with 3000 C design temp connected to a pump, Define the line Criticality? Calculate the Sc and Sh values for A106-Gr B material with 2600C design temp? For a given size of pipe and thickness bend with a larger radius will have higher SIF. True or False. A material with higher number of cycles has higher allowable stress than a material with lower number of cycles . True or false. Addition of elbows in general (a) increases or (b) decreases sustained deflections and stresses. Mention (a) or (b). A cantilever 10 std sch. stainless steel empty pipe (w/o insulation) is heated to 200 Deg.C. What are the sustained and thermal stresses ?

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Thank You

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