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

-Category 3 (Computer Analysis).

Acceptable?

No

Revise the Piping Layout & Isometric

-Modify pipe support type and location.

-Category 4 (Approximate Method).

-Category 5 (Visual Exam.).

Yes

-Add elbow to increase piping flexibility.

Review and Comment on Conceptual Studies

-Stresses are within allowable. -Nozzle loads are within allowable. -Anchor and guide support location are already fixed and already informed the loading values to Civil Department.

Review 3D Model and Support Scheme

-To prepare pipe support selection.
-To select pipe support based on pipe support selection criteria. -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. Category 4 Using approximate methods such as: the Kellogg, Grinnell or Tube Turn methods.

2.

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

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

Mt 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

Force

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

4. Pipe Support

Sliding Support

Control Valve Tight Support Variable Spring Support Adjustable Guide

4.1. Support Around Control Valve

4.2. Spring and Adjustable Support

Pad Shoe

Sliding Plate

4.3. Hold Down Guide 4.4. Anchor

Eye Bolt

Structure

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

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

ASME: The American Society of Mechanical Engineers API: American Petroleum Institute

NEMA: National Electrical Manufacturers Association

WRC: Welding Research Council

6. Pipe Stress Analysis using Caesar II 4.50

6.1. Required Data:

Spring Support

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.

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:

1. 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 timedependent stress rupture due to sustained load. Excessive load causes plastic deformation and rupture.

Secondary Load Characteristics:

1. 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.

2. 3. 4.

2. 3. 4.

5.

5.

7.2. Code Stress Equations

7.2.1. B31.1 Power Piping 7.2.2. B31.3 Process Piping

S sus
S EXP

0.75iM A Pdo SH Z 4t

S sus
S EXP

Fax [(ii M i ) 2 (io M o ) 2 ]1/ 2 Pdo SH Am Z 4t

2

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

0.75iM A 0.75iM B Pdo kSH Z Z 4t

[(i M ) 2 (io M o* ) 2 4 M T ]1/ 2 i i* S A f (1.25 SC 1.25 S H S SUS ) Z

SOCC
Where:

SOCC S SUS Sl 1.33 S H

Where:
Fax= Axial force due to sustained, kg 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/mm2 ii ,io = In-plane, out-plane intensification factor MT = Torsional moment due to expansion, kg-mm SA = Allowable expansion stress, kg/mm2 SC = Allowable stress at installation temperature, kg/mm2 Sl = Bending stress due to occasional loads such as wind/earthquake f = Stress range reduction factor

MA = Resultant moment due to sustained, kg-mm SH = Allowable stress at operating temperature, kg/mm2 i = 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 S Yield

SEXP (Sb* 4St )1/ 2 0.72SYield
2 2

S sus Slp Sb 0.75 S x F x T

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

2 2

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

SOPE S EXP S SUS S

SOCC Slp Sb** 0.75 x 0.72 x k x S Yield

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

S OCC S lp S b** 0.75 x S x F x T x k

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

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

E
a

= Modulus of Elasticity
= Thermal expansion coefficient = Poissons ratio

T = Temperature derating factor

k = Occasional load factor

T = Temperature change of pipe from ambient v

SH = Hoop stress kg/mm2 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 Fy = 125 Dc Fz = 100 Dc Mx = 250 Dc My = 125 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: 1. 2. Shortest suction line shall be planned to minimize pressure loss. 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. Care shall be taken in thermal stress calculations because the entire piping does not always have the same temperature, depend on operation plan. 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.

3.

4.

Adjustable Support

8.3. Around Reactor and Fired Heater

Reactor

Constant Hanger Lift Off Sway Brace Items to be concerned: 1. Piping shall be designed to have sufficient flexibility but it shall be arranged as short as possible. 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. 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.

Constant Hanger

2. Sway Brace

3. Adjustable Guide Fired Heater

8.4. Around Compressor

Items to be concerned: Re-strut Re-strut Compressor Compressor 2. Adjustable Guide Adjustable Guide 3. 1. Piping route shall be flexible to prevent excessive forces and moments on the compressor nozzle. Piping support shall be installed well balanced so no excessive forces and moments on the compressor nozzle. Piping connected to and from suction and discharge of compressor shall be equipped with vibration proof as required. Vibration proof piping support shall allows piping movement caused by thermal expansion and prevent piping vibration caused by compressor. 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. To check the natural frequency of piping system against compressor. Expansion joint shall not be used for vibrating line which may cause damage.

4.

5. Vessel

6. 7.
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. Piping route shall be flexible to prevent excessive forces and moments on the AFC nozzle. 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.

2.

3.

AFC

4.
Stopper

Vibration due to slug force can be eliminated by install properly stopper and guide support.

Vessel

THE END