BASICS OF PIPE STRESS ANALYSIS: A PRESENTATION-Part 1 of 2
BASICS OF PIPE STRESS ANALYSIS: A PRESENTATION
Contents
1. Objectives of Pipe Stress Analysis
2. Governing Codes and Standards
3. Stresses in a Piping System
4. Reducing Piping Stresses
5. Basic Allowable Stress
6. Loads on a Piping System
7. Work Flow Diagram
8. Stress Criticality & Analysis Method
9. Piping Stress Analysis using Software Caesar II
10. Type of Supports
11. Questionnaire
1) OBJECTIVES OF PIPE STRESS ANALYSIS:
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
Optimal Design:
Avoiding excessive flexibility and also high loads on supporting structures. Aim towards
an optimal design for both piping and structure.
2) 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:
ASME B31.3: Process piping Code
ASME B31.1: Power Piping Code
Centrifugal Pumps: API 610
Positive Displacement Pumps: API 676
Centrifugal Compressors: API 617
Reciprocating Compressors: API 618
Steam Turbines: NEMA SM23/ API 612
Air Cooled Heat Exchanger: API 661
Fired Heaters: API 560
Flat Bottom Welded Storage Tanks: API 650
Heat Exchangers: TEMA/ Vendor Specific.
Vessel/Column: Vendor Specific
3) STRESSES IN A PIPING SYSTEM:
Sources for generation of stress in a Piping System:
Weight
Internal/External Pressure
Temperature change
Occasional Loads due to wind, seismic disturbances, PSV discharge etc.
Forces due to Vibration.
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 x W ”. Where, Sh=Basic allowable stress at maximum
metal temperature expected during the displacement cycle and W=weld joint strength
reduction factor.
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
equation (Clause 304.1.2) mentioned in Fig.1:
Fig. 1: Equation for Thickness Calculation for Straight Pipe based on ASME B 31.3
Change in length of a pipe of length L due to temp change (ΔT) is given by ΔL=L α
ΔT Here, α =Co efficient of thermal expansion = change in length of unit length element
due to unit change in temp.
Two “α” 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 (μin/in/0F).
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 equation
SE = ( Sb^2+4 St^2)^0.5 per equation 17 from ASME B31.3( clause 319.4.4).
This SE value shall not exceed SA value where SA= Allowable Displacement Stress
Range.
As per ASME code B 31.3 (Clause 302.3.5) the allowable displacement stress range (SA)
can be given by the equation (Fig.2):
Fig.2: Equation for Displacement Stress Range Allowable
Here, f= Stress range reduction factor and Sc=basic allowable stress at minimum metal
temp
When Sh > SL , the allowable stress range is calculated by the following equation (Fig. 3):
SL=Longitudinal Stress due to sustained loads.
Fig.3: Equation for Liberal Displacement Stress Range Allowable
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”
Code does not explicitly explain the stresses generated due to vibration.
The vibration problems are solved by engineering judgment and experience.
4) 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): Refer Fig. 4
Fig.4: Flexibility Check Equation for Simple Systems
5) Basic Allowable Stress:
Minimum of (As per ASME B 31.3)
1/3rd of Ultimate Tensile Strength (UTS) of Material at operating temperature.
1/3rd of UTS of material at room temperature.
2/3rd of Yield Tensile Strength (YTS) of material at operating temperature.
2/3rd of YTS of material at room temp.
100% of average stress for a creep rate of 0.01% per 1000 hr.
For structural grade materials basic allowable stress=0.92 times the lowest value
obtained from 1 through 5 above.
Loads on a Piping System:
Static loads are those loads which acts very slowly and the system gets enough time to
react against it. Examples of static loads are shown in Fig.1
On the other hand dynamic loads acts so quickly that the system does not get enough
time to react against it. Examples of dynamic loads are shown in Fig.2
6) Work Flow Diagram:
The interaction of Piping Stress team with other disciplines in any organization are
shown in Fig. 3:
Fig.3: Inter Departmental Interaction with Stress Team
7) Stress Criticality and Analysis Methods:
Highly Critical Lines (Steam turbine, Compressor connected pipelines): By Computer
Analysis
Moderately Critical Lines (AFC connected lines): By Computer Analysis
Low critical Lines : Visual/Simple Manual Calculation/Computer analysis and
Non Critical Lines: Visual Inspection
8) 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
Soil Characteristics from civil for underground analysis
Nozzle load limiting Standards
Plot Plan for finding HPP elevation and equipment orientation.
Governing Code
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.
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.
Output:
Final marked up Iso’s 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
9) Type of Supports:
Rest
Guide
Line Stop
Anchor
Variable Spring Hanger
Constant Spring Hanger
Rigid Hanger
Struts
Snubbers
Sway Braces etc
10) 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.?
Calculate the minimum pipe thickness of a seamless 10” NB A106- Gr B material with
design pressure of 20 bars. (Design Temp= 350 degree C and Corrosion allowance= 1.6
mm)?
