Fundamentals of Pipe Stress Analysis - Workshop 1
Fundamentals of Pipe Stress Analysis - Workshop 1
Organiser:
Presenter:
Amrit Pal Singh, CEng MIMechE
Email: aps.piping@gmail.com
The objective of piping stress analysis is to ensure safety against failure of the
Piping system by verifying the structural integrity against any loading conditions
expected to occur during the lifetime of the system.
(1)Sustained
(2)Thermal.
(3)Occasional.
(4)Internal & External forces.
(5)Imposed displacements.
(6)Loads on connecting Equipment
(7)Loads on Supports & Structure.
(8)Leakage at joints.
(9)Vibration.
(10)Overstress & fatigue.
[ 2 ]
Objectives (cont.)
(1)Simplified methods
e.g., Accepting the layout on the basis of
his past experience.
(2) Approximate method.
e.g., Simple cantilever Method, Guided
Cantilever Method, Nomographs,
Manual Calculations.
(3) Performing a comprehensive analysis.
e.g., Computer Analysis.
Objectives (cont.)
Projects Stress
Plan / Schedule Stress criteria, Critical Line list
guidelines & procedure & Stress Index
Process
P&ID
Isometrics Support
Standards
Piping Specifications
Speciality items
Support selection Support design
Requisitioning
Plant
coordinates
Boundary
Node conditions
numbers
Loads for
Structure design
Excessive
displacements
Support
marking
Actual &
Allowable Stress
Notes
Process Coordinate Calculation
conditions system details
Stress Isometrics (sample) [ 5 ]
Calculation
Continuation until
fixed anchor location
1. Pipe size
2. Pipe configuration
wL wL2 5wL4
A R MC d
2 384EI
L 8
w
wL wL2 wL4
B R ME d
2 12 384EI
L
w
Where,
C wL wL2 2.5wL4 L = Length between two
R MC d
2 9.3 384EI supports, in
L L L L
w = Total weight of the pipe
per unit length, lb/in
F
R = Reaction
M = Bending moment, in-lb
R F ME Fb Fb2 3L b
D d (End, Center, Load)
b a 6EI F = Concentric load, lb
L
w
5wL wL2 wL4
E R ME d
8 8 185E.I
L
F
Fm1m2
d
Fb Fab 27EIL
F R ML
b a L L m1 ab a 2b
L
m2 3a a 2b
Where,
fmax = 25 N/mm2
[ 7 ]
Pipe Span table & Reduction factors (sample)
• Support location should be selected near the existing building steel to minimize
the use of supplementary steel.
• The standard span does not apply to vertical run pipes (risers) since no moment
and no stress will develop due to gravity load in the riser.
• Provide space for adding loops to piping near load sensitive equipment, e.g. in
pump suction lines.
• Consider the need to add friction reducing slides between the piping and
support steel.
• Provide supports near instruments, and other devices that are likely to be
removed for maintenance.
Additional Foundation
required.
WRONG
RIGHT
SS Plate
PTFE pad
Pump piping & adjustable supports [ 11 ]
Settlement consideration
Adjustable
support
(preferred)
Piping Flexibility arrangements [ 12 ]
Stiff Piping
Expansion Loop
NOT recommended for pipes ‘U’ Type
subject to temperature changes
Expansion Joint
Flexible Piping
- Speciality Item.
Helps to reduce loading at Nozzles - Requires Pressure Thrust Calculation.
- Adds cost.
‘L’ Type or ‘Z’
Type NB: It is recommended that if the
layout of the piping system
provides inherent flexibility
through change in direction.
Leg arrangement
Restraint Types
Definitions:
FS
S+3 Circumferential or Hoop
SAX MT
Pressure Stress (Sustained):
S/3 PDo
SHP
2Et
Longitudinal Stress due to
Sustained Loads (SL Sh):
P P Longitudinal Pressure Stress:
PDo
ZS SLP
5 4t
S/3
S/ Axial Stress:
FAX
SAX
S% S3+ Y A
S3+ Bending Stress:
MB
A = Area of cross-section, in2
X S/ SB
S7 Z
E = Weld factor
Maximum Shear Stress:
F = Force, lb (AX = Axial, B = Bending, S = Shear)
(319.4.4.(a)(17)
MB = Moment, in-lb (B = Bending, t = Torsional)
Q.FS M t
P = Internal Pressure, psi Sshear
A 2Z
Q = Shear Form Factor (1.33 for circular sections)
Note: Radial Stress is considered
t = Wall Thickness, in negligible for thin-walled pipes
Z = Section Modulus of Pipe, in3 (D/t 0.6)
SA f> 1.25Sc Sh SL @
Where
Sc = Allowable stress for piping material when cold.
Sh = Allowable stress for piping material at the design temperature.
f = stress range reduction factor
f = 6.0(N)ï0.2 1.0,
where N is some number of cycles from 7000 to 2 million.
S L S AXO S BO 1 . 33 S h
FAXO
where: SAXO = Axial load due to occasional loads. SAXO
A
MBO
SBO = Bending moment due to occasional loads. SBO
Z
PDO FAX MB
SL Sh
4t A Z
[ 16 ]
Stress Strain curves
Total Elongation
Elastic
Uniform Neck
Range
Elongation Down
1 1 2
3
2
V
V E
4 5
H H
Expansion Stress:
SE SB2 4 ST2 d SA
Where,
2 2
ii Mi io Mo
SB
Z
Mt
ST
2Z
i = Stress Intensification Factor
(i = In-plane, o = Out-plane)
FAX
SAX
A
B31.3 Stresses in Bends & Tees [ 17 ]
Q&A
[ 18 ]
Understanding CAESAR
Start
CAESAR II
Error
No
Output
• Graphical display
• Displacement
• Numerical display
• Load
• Report
• Stress
End
[ 19 ]
Getting Started
• Start CAESAR II
Main Menu
Working folder
Toolbar
Menu bar
Identify version
& build
[ 20 ]
Input Menu
Analysis Menu
[ 21 ]
Output Menu
Output Menu
Animation Graphics
Load
cases
[ 22 ]
External Interface Menu
Getting Help
• User Guide , Technical Reference,
Application Guide
• On-line documentation
• F1 on the cell of interest
• Tool tips show dimensions
Input mode
Element
specific data Menu bar Toolbar
Next, or if
last Create
Next
<Ctrl> End
First If Last,
duplicate
Page Down
Previous Last
Next
Page Up (or Mouse Wheel)
<Ctrl> Home
Plot Tools
•The solution phase commences with the generation of the element stiffness matrices
and load vectors, and solves for displacements, forces and moments, reactions, and
stresses.
•This solution phase also performs the design and selection of spring hangers, and
iterative stiffness matrix modifications for nonlinear restraints.
Q&A
[ 28 ]
*Problem Solving Workshop – detailed example where each participant works independently,
applying what is learned to solve a variety of stress and equipment load problems.
Calculated Piping forces and moments at equipment nozzles shall not exceed the
allowable limits. These limits should be mutually agreed with the manufacturers and
the client.
Equipment Evaluation Criteria or Standard
Rotary positive displacement pumps API 676
WRC-107
“Local Stresses in …Shells due to
External Loadings” - based on Professor
Bijlaard's theoretical work, with some
adjustments made based on available
experimental data
Pipe Hangers & supports can be broadly classified into the following categories :-
Constant supports/
hangers
Dynamic restraints/
Rigid struts
Rigid hangers/Supports
Snubbers / shock absorbers. Variable supports / hangers Spring Loaded sway braces
Hangers
Spring Design [ 32 ]
CL = HL + k Ʀ
Load Variation
• Load Variation = Load Change relative to Hot Load.
| HL – CL | |kƦ|
LV = -------------- = --------
HL HL
Where:
Ʀ = Travel
k = Spring rate
HL = Hot Load
CL = Cold Load
Single bellow
Universal bellow
[ 34 ]
Expansion Joints – Pressure Thrust
Dual Unrestrained
Application
The force required to compress or expand the expansion joint in the axial direction Fm is:
2 AUV 2 T where
Fp sin
g 2 A = internal area of pipe, sq in.
U = density of fluid, lb/fe
V = velocity of flow, ft/sec
g = acceleration due to gravity = 32.2 ft/sec2
T = angle of bend
• Fatigue
• Creep-fatigue
• Burst, collapse, over stretching
• Corrosion
• Design Factor = 2.6 on cycles, 3.0 on burst, 2.25 squirm
After one of the reactors cracked, it was decided to temporarily replace the faulty reactor with a “bypass” pipe. To allow
for thermal expansion and because each reactor was fixed in the place, the short interconnecting pipes, which joint the
outlet nozzle of the reactor R4 to the inlet nozzle of the reactor R6, were fitted with bellows B4 and B6.
The interconnections were horizontal but the bypass was constructed with a sloped middle section in order to bridge the
vertical shift between the nozzles. The unbalanced horizontal forces that result from such an arrangement led to stresses
on the bellows and bypass arrangement for which it was not designed.
The catastrophe was initiated by a rupture of the bypass at the upstream bellows B4 due to fatigue. The rupture caused
an accidental release of cyclohexane and subsequent formation of vapour cloud containing about 30 tonnes of this
chemical. The cloud exploded causing 28 fatalities, the near total destruction of the 24 hectare plant, severe injury to the
population outside the plant.
[ 39 ]
Piping vibration is the to and fro displacement of pipe body in lateral bending
and/or shell wall resonance modes under the effect of dynamic loads.
k
Natural Angular frequency Z 2S f
m
Resonance
f/fn ~ 1.0
+
• Amplitude of this
Time
resonant vibration
depends on the
component's damping.
• Higher the damping, the
lower the peak.
• Resonance causes high
cyclic stress, therefore,
_
should be prevented.
To enter the dynamics input, the proper job name must be current prior to selecting
the Analysis-Dynamics file options of the Main Menu.
• Dynamic initialization
• Eigensolver - calculates the
natural frequencies and modes
of vibration.
• Each natural frequency appears
on the screen continues until the
frequency cut-off is exceeded
or the mode count reaches its
limit.
• Sturm Sequence Check - to
confirm that no modes were
skipped. If the check fails,
increase the frequency cut-off
value.
Mode shapes
In-Salah Gas Flare Incident, Sonatrach, Algeria [ 43 ]
Description:
In Salah Gas (ISG) is a Joint
Venture between : Sonatrach
(35%), BP (33%), Statoil (32%).
Proposed mitigation:
• Adequate bracing or supporting
• Thicker wall pipe
Purpose:
Safety-relief valves are installed for the purpose
of protecting the fluid system from accidental
over-pressure, or venting the fluid generated in
excess of requirement.
References:
API 520, Appendix II of ASME B31.1, ASME III (NC
& NB 3677)
CLOSED OPEN
Out of balance Forces [ 44 ]
F3
F3
F4
F1 F1
F1+F2
Closed System
Open System
F PA mV 2 Where:
A = Orifice Area, mm2.
kT Cp = specific heat at constant pressure.
F1 129W 0.1 AP
k 1 u M Cv = specific heat at constant volume.
F = reaction force at Orifice, N.
kTR k = ratio of specific heats (Cp/Cv).
F2 0.6 W
M M = molecular weight of the process fluid, kg/kg mol/K
P = Set pressure, in bar (g).
T R
F3 W2 u R = Gas constant (8314 J °Kï1 kmolï1)
PAM
T = temperature at inlet, in degrees Kelvin.
F4 2F1 W = flow of any gas or vapour, kg/sec.
Surge
Potential consequences:
• Pipe over pressure
• Pipe collapse
• Flange leaks
• Valve leaks
• Vacuum / Cavitations
• Large pipe movements.
B 31.3 requirements:
• As per 301.2.2, the effect of such pressure surges must be considered and
kept within the allowable pressure limits of the piping system.
• As per 302.2.3.6, if surge loads are occasional then the total permissible
design pressure is 1.33 times the Design pressure. (1.1 times as per B31.4)
Force Direction
P
V
P+'P
V+'V
gK
c 12 (ft/sec)
U
Fluid velocity: Q
V (ft/sec)
A
where
g = gravitational constant (32.2 ft/sec2)
K = bulk modulus of liquid, psi (about 300,000 psi)
U = Density of fluid (lb/ft3)
= Density of water (62.4 lb/ft3) x Specific gravity
Q = Fluid flow rate (ft3/sec)
A = Flow Area (in2)
2L
During slow valve closure: T !
c
U LV (psi)
Maximum Surge pressure is at the valve 'P
gT
Li
Surge pressure upstream = 'P (psi)
L
where
Li = Length of pipe from source to the point of interest (ft)
(assuming Linear reduction in flow with time)
L = effective length of pipe (ft)
T = Valve closing Time (sec)
Static force on a 90° elbow due to steady fluid flow [ 49 ]
2 UAV 2 T
F sin
g 2
1.414 UAV 2
T
g
where
U = density of fluid (lb/ft3)
A = cross-sectional flow area (ft2 )
F
V = velocity of fluid (ft/sec)
g = gravitational constant (32.2 ft/sec2)
1.414 UAV 2
The total loading on 90° elbows (lb) 2 A'P
g
0.765 UAV 2
The total loading on 45° elbows (lb) 2 A'P
g
Sample Problem
INPUT
Q = 4 ft3/sec Flow Rate
Tclosure = 2 sec Time for closure of Valve
DO = 12 in Pipe O.D.
t = 0.39 in Thickness of Pipe
G = 37.46 lb/ft3 Density of Fluid
L = 3300 ft Length of Pipeline
K = 300000 psi Bulk modulus of Fluid
DLF = 2 Dynamic load factor
OUTPUT
c = 6094 ft/sec Wave Velocity
A = 98.74 in2 Internal C.S. Area of Pipe
V = 5.83 ft/sec Velocity of Fluid
T = 1.083 sec Valve closure time (If T>Tclosure then it is instanteneous closure, else late closure)
' pLATE = 15.55 psi Surge Pressure of the valve during late closure.
' pINST = psi Surge Pressure of the valve during instateneous closure.
The time related dynamic forces caused by the pressure surges can be calculated
using computer programs.
Possible cause:
•Vacuum due to vapour condensation
•probably due to water-column separation
•Uncontrolled pump shut down
•Inadequate wall thickness
•Inadequate stiffeners or reinforcements
Flow regimes
10
Liquid velocity (m/sec)
Stratified flow
1
0.1
Stratified wavy flow
0.01
0.1 1 10 100
Gas velocity (m/sec)
Slug force is the impact load caused by the change in momentum of the
moving liquid mass when pushed by the gases in between.
F
L F2
U V
F1
T
2 UAV 2 T
Slug flow force, F mass x velocity sin
g 2
Mitigation:
•Axial restraints in all directional changes of pipe run within the loop.
•Recommended minimum natural frequency of the pipe = 4 Hz.
Q&A
[ 53 ]
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