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World Academy of Science, Engineering and Technology

International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol:10, No:5, 2016

Design and Analysis of Piping System with Supports
Using CAESAR-II
M. Jamuna Rani, K. Ramanathan

 A significant research on piping systems, span length,
Abstract—A steam power plant is housed with various types of number of supports, and cost of the piping layout had been
equipments like boiler, turbine, heat exchanger etc. These equipments studied by [2] using CAESER-II software. He optimized the
are mainly connected with piping systems. Such a piping layout number of supports by changing temperature and pressure
design depends mainly on stress analysis and flexibility. It will vary
within operating medium, density of pipe material and the
with respect to pipe geometrical properties, pressure, temperature,
and supports. The present paper is to analyze the presence and effect span length between the supports. It was reported by [3] that
of hangers and expansion joints in the piping layout/routing using by modifying the layout of steam piping system, the pressure
International Science Index, Software and Systems Engineering Vol:10, No:5, 2016 waset.org/Publication/10004702

CAESAR-II software. Main aim of piping stress analysis is to drop can be minimized and hence power can be minimized in
provide adequate flexibility for absorbing thermal expansion, code thermal power stations. Due to the layout changes, the hanger
compliance for stresses and displacement incurred in piping system. supports position also changed. A research on pipelines with
The design is said to be safe if all these are in allowable range as per
an aim of maximizing the distance between supports,
code. In this study, a sample problem is considered for analysis as per
power piping ASME B31.1 code and the results thus obtained are minimizing the number of supports and reducing the total cost
compared. of erecting these pipe supports was done by [4] with
mathematical calculation. Shweta Bisht et al. [5] have given
Keywords—ASTM B31.1, hanger, expansion joint, CAESAR-II. the basic ideas about the piping analysis software CAESAR II.
The design and analysis of piping systems using software was
I.INTRODUCTION explained elaborately in this work. The benefits of using

P IPING stress analysis is a method which is highly FRPC and interaction between the different stresses on the
reciprocal with piping layout and support. In piping pipe walls were analyzed by [6]. It was reported that carbon
system, the layout should be performed with the concern of composites pipes improved ultimate internal pressure capacity
the piping support and stress in mind. It shows sufficient of pipes. The possibilities and disadvantages of finite elements
flexibility for thermal expansion in pipe routing so that various methods in steam pipeline stress analysis were founded by [7].
simple and economical pipes can be build using various piping The basic concept of flexibility such as flexibility
materials & section properties which includes pressure, characteristics, flexibility factor and stress intensification
temperatures & loading. The required layout should be factor (SIF) for any code using CAEPIPE software was
perfectly balance between stresses so that layout efficiency is explained by [8].
achieved. After piping layout is made, piping support system A.Need of Pipe Supporting
is determined. Various support locations & types should be The objective of the pipe supports design phase is to
repeatedly iterated until all the stress requirements were prevent the following:
satisfied with piping allowable (e.g., nozzle loads, valve • maximum stress occurring in the piping
accelerations, and piping movements). • excessive forces on equipment
The piping supports are designed based on the selected • excessive interference with thermal expansion
locations, types and the applied loads. The discussion is • excessive pipe sag
heavily weighted to the stress analysis of piping systems in • excessive heat flow, exposing support to temperature
thermal power plants, since this type of piping has the most outside their limits.
stringent requirements. Emphasis was given in the literatures only on piping
Basavaraju [1] has carried out research on piping systems, systems and its layout and there were no report giving
supports, materials used, fittings, insulation properties, emphasis to piping supports. As for as steam piping is
operating medium in pipe line and analyzed the main Stream concerned, there are so many supports that can be used in the
line of thermal power plant. Hanger is mainly used in the piping system and it should be selected based on the position
analysis of the piping systems. and as per ASTM codes. In this paper, the piping supports
mainly used in industries such as hanger, expansion joints and
restraints were considered with an objective of better
K. Ramanathan is Assistant Professor in Department of Mechanical
Engineering at the Alagappa Chettiar College of Engineering and Technology, flexibility and reduced stress. The analysis is performed using
Karaikudi, Tamil Nadu, India 630004 (e-mail: ramsananthi@gmail.com). CAESAR II software [10]. Among the various types of
M. Jamuna Rani is P.G. Scholar (ME-CAD)in Department of Mechanical hangers, variable supports are preferred for use in power
Engineering at the Alagappa Chettiar College of Engineering and Technology,
Karaikudi, Tamil Nadu, India 630004 (phone: +91 8870385942, e-mail: plants [11].
jamuna.aero@gmail.com).

International Scholarly and Scientific Research & Innovation 10(5) 2016 973 scholar.waset.org/1999.8/10004702

imppact qualitiess. A considered for thee analysis of piping p stress with w supports. annd P91.. When the displacem ment is otheer equipment items necessaary to preventt overstressingg the larrge.60 m max 2. These coodes contain basic pipiing stress anallysis. Chrome-Molly) is a TAB BLE I PROPERTIES OFF PIPE ROUTING seeamless ferrittic Alloy-Steeel Pipe for high tempeerature C COMPOSITION seervice.87- 0. Mainly thee pipe • Insulation deensity: 240 kg//m3 enngineer is to consider the stress analysis according to the T The geometricc properties of piping syystem are directly pipping codes. Software and Systems Engineering Vol:10. and 1/4'' to NPS 48''. International Science Index. resistance too wear. • Working tem mperature: 540°C • Pipe size: D2219. For integrity and ooptimal desiggn.90. World Academy of Science. Mechatronic and Manufacturing Engineering Vol:10. reference data.60 1. By fiixing a guuide rod at thhat fixed poinnt. guuide rod whenn it exceeds the design vaalue in the case of relieef devices annd fittings. supports and loads. Molybdenum m increases the resistance to 40. vaalves. Aerospace. operaational the material libraary available in the CAES SAR software. piping laayout is to be m modeled first. Usually chroome moly pipees are referredd as “P SA A335 0.30. TThe propertiess of pipe rouuting material are presenteed in Molybdenum m increases thee strength of steel as well as the Tabble I.. P22. seecondary. Engineering and Technology International Journal of Mechanical.50 1. andd peak.1 Power Pipingg Code deesign and stress analysis. Industrial. No:5. 1 Pipingg Routing with H Hanger Supports ASTM A3355 P22 Pipe (AS SME S/A335. It includes suppports. P9.0255 0. Maaterial flaanging (vanstooning). 2016 waset.8/10004702 . the possibble damage ccan be • Design pressure: 210 bar avvoided since it enables sufficient strrength againsst the • Working meddium: Sh steam m geenerated thrustt force..waset. boltingg. Design requirements r oof this Fig. Normaally the thrustt force presssure-containinng componentts. In I piping systeem SA335 P222 is selected from Thhe pipe stress depends upon structural inntegrity.13 Grrade” pipes annd few populaar categories arre P5. and sim milar formingg operations. International Scholarly and Scientific Research & Innovation 10(5) 2016 974 scholar. giveen to the softwware. 00.org/Publication/10004702 matterial library.1x8. andd equations nnecessary for piping 1 iss the piping layout availaable in literatture [1] whicch is ASME B31. cooncerns in thiis piping systeem. formulas.org/1999. Fig. hangerss and emmploying single expansions joints. 0. The maaterial is to be selected from m the Thhe major stresss categories aare primary. 2016 The displaceement in the expansion jooint is restrictted by codde cover thosee for pipe. Pipe off this specificaation shall be ssuitable for beending. double jooints are prefferred. flaanges. T The wall thickkness is considdered as schedduled haardenability. P111.17 II.Piping Routiing Parameterrs wiill react at thee fixed point oof the expansioon joint. No:5.05. sooftening. prroduced by thhe displacement reaction annd internal prressure A A.M MODELING • Pipe materiall: SA 335 P222 • Pipe density: 0. restraains grain growwth.15 0. It depends uponn the material. The size of the material to be used commonly is NPS elaastic limit. anda for C Mn P S S Si Cr Mo fuusion welding.0078 kg/ccc In the pipingg systems varioous failure moodes is to affeect the • Insulation: 1000 mm ovverall functionn of the pow wer plant [9]]. 0.025 P P22 0. gaskets.

waset.RESULT AN ND DISCUSSION N A A. 4//Lin. N Nodal displaceement (DXin. World Academy of Science. DYin.4 an iimportant paraameter in the sstress analysiss of piping sysstem.7@Node 220 mayy safely be appplied to a pipee. Allowable sttress of material is  Code Stresss: 5262. psi. It is dividded into two bbranches and one o end is withh the PSS = Pipe Stifffness.5@ @Node 18 andd standard. in anchhor. in.149r3 softtware. Jann 29.7% at Node 20. Foor analyzing the piping layout withh expansion joint Fig. Tabble III. the stress values Force/Load annd moment att hanger locaations can also be F weere changed aat every nodee in the routinng. E = Modulus off Elasticity. Main aim off the analysis is to The pipe stifffness equatioon is commonn for any pipee lines. 2 Modeledd Piping System ms with Hanger Support in CAE ESAR II Softwaare The output off the piping annalysis is detaiiled below.6@Noode 30 exceeed an allowabble stress of thhe material forr the selected code  Bending Sttress: 4195. Raatio of the pipe routing is deefined as International Scholarly and Scientific Research & Innovation 10(5) 2016 975 scholar. r = Meaan Radius of P Pipe. I=772. R=4. I = Trannslational Dirrectional (y+) and other ennd connected with M Moment of Ineertia of pipe perp Unit. The staarting of the ppiping system is connected with nozzle.org/1999.232 simu mulated with suustained type oof loading systtem and the ouutput paraameters such displacement at various pooints. Moment andd force at haanger International Science Index. III. psi. Engineering and Technology International Journal of Mechanical.Piping System m with Hangeer Support E= 3. Thhe model is then 0. 2016 allo owable stress  Code Stresss Check Passeed: Loadcase 4 (SUS) W+P11+H  Highest Strresses: (lb. reduuce the flexibiility and the sttress in the pippe layout.49 in.org/Publication/10004702 locaations were allso analyzed.0@N Node 20 rotaation (RXdeg. Industrial.8/10004702 . 2016 B. in. T The design of piping layoutt is modeled using u CAESA AR-II PS = E El/0. DZin) and  Torsion Strress: 837. The ratio of the obtaained from CAESAR-II C ssoftware and are presenteed in pippe routing obbtained in the analysis was 31.1= B31. torrsion.0@Node 18 softtware are preseented in Tablee II./sq. Pipe stiffnesss is calculated using: rotaational and meean radius are to be fed into the software.0 Working stress (ccode stress) inn the piping system s shouldd not  Axial Stress:1285.) T The allowable stress is the maximum m forcee per unit areaa that  Ratio (%): 31. No:5.1 149 ∗ 4. No:5. RZdeeg) in all thee three directtions  Hoop Stress: 2602. 2 is a pipinng layout incoorporating ninee hangers whiich is 3.06 6 ∗ 10 ∗ 72. L= Length of Piipe.1 -2016.2232 in F Fig.5@Noode 14 obtaained from thee analysis of ppiping system using CAESA AR-II  Max Stress Intensity: 78550.49 moddeled using C CAESAR II software. Software and Systems Engineering Vol:10. Based on thee pressure annd temperaturee. bending. stressess and 1 19.in. D = Mean Diameeter of Piipe.  Piping Codde: B31.64 ∗ 10 nozzle loads weere observed. RYdeg. Aerospace. Mechatronic and Manufacturing Engineering Vol:10.Pipe Stiffneess Calculatioon for Expansion Joints infoormation such as stiffness vvalue for axial.06E7. 2016 waset.  Allowable Stresses: 166000.

019 --0.0221 -0.0222 -0.6@Node 60 660 -0.018 --0. There are three ttypes of anaalysis N Node DX in.101  Code Stress Check C Passed: Loadcase 2 ((SUS) W+P1 338 0.032 0.019 --0.053 550 -0.111 0.048 -0.002 0.254 0.106 beloow.018 --0. Mechatronic and Manufacturing Engineering Vol:10.02 --0. MZ Z ft.113 Theermal run willl be useful to study the dissplacements whichw 11 0. lb.lb.0003 -0. No:5.015  Max Stress Inntensity: 60899.001 0.151 0.8/10004702 .037 0. MY ft.018 0.6 0 16. 11 ProgDesignn VSH 4(SUS) 0 -792 0 0 0 0 obtaained from CAESAR-II C ssoftware and are presenteed in 21 ProgDesignn VSH 4(SUS) 0 -381 0 0 0 0 Tabble IV. 2016 TAABLE II pipee routing w with hangers and restraiints modeledd in NODAL DISPLACEEMENT AND ROTA ATION OF PIPING SYSTEM WITH HA ANGER SUPPORT – CA AESAR II OUTPUUT CAE ESARII softw ware./sq. FY lb.112 floww.158 0.001 661 -0.105 1141 -0.303 -0.228 -0.021 --0.227 0.252 0.009 0.03 0.776 -1. weight ruun and final run. ft.709 0.406 -1.241 0.145 -0.821 -1.108 -0.9 21 Rigid Y 2(SUUS) 0 3500 0 0 0 0 1102 Rigid ANNC 4(SUS) 0 -280 0 0 0 0 31 Rigid Y 2(SUUS) 0 -983 0 0 0 0 1141 Rigid ANNC 4(SUS) 0 -190 0 0 0 0 40 Rigid +Y 2(SU US) 0 -18000 0 0 0 0 1151 Rigid + +Y 4(SUS) 0 0 0 0 0 0 51 Rigid Y 2(SUUS) 0 -518 0 0 0 0 70 Rigid ANC 2(S SUS) 0 -152 0 -1.158 0. 22 ProgDesignn VSH 4(SUS) 0 -902 0 0 0 0 TAB BLE IV 31 ProgDesignn VSH 4(SUS) 0 -798 0 0 0 0 NODDAL DISPLACEME ENT AND ROTATIOON OF PIPING SYST TEM WITH EXPANNSION 41 ProgDesignn VSH 4(SUS) 0 -385 0 0 0 0 JOINT AND D RESTRAINTS SUUPPORT – CAESAR R II OUTPUT 51 ProgDesignn VSH 4(SUS) 0 -315 0 0 0 0 Nodde Load Casee FX lb.02 --0.0112 -0. Output of thhe pipe routingg for 222 0.062 0. Fig.lb.021 --0.018 --0.311 -0.04 0.034  Torsion Stresss: 573.056 0.034 0.019 --0.201 0.org/1999.001 0.082 -0.223 0.154 0.156 0. 2012 331 0.092 1101 0.086  Ratio (%): 200.104 1111 0.0222 -0.waset.082  Axial Stress: 1323.105 1140 0.066 0.1 = B31.018 --0.172 0.072 0.391 -0.044 -0.1 -2012.38 0.255 0. RY deg.5@Nodde 19 559 -0.019 --0. RX deg.03 0.333 -0.158 0. 3 Modeled Piiping System with Expansion JJoint and Restraaints LO OAD AND MOMEN NT ON PIPING SYST TEM WITH HANGEER SUPPORT.02 --0.019 --0.316 -0.08 0.222 -0.391 -1.lb.Piping Systtem with Expaansion Joint annd Restraints 1111 Rigid Y 2(SU US) 0 -325 0 0 0 0 Piping system m incorporatinng two expannsion joints annd five 1311 Rigid +Y 2(SU US) 0 -188 0 0 0 0 restraints are m modeled to thhe same geom metry and sim mulated wiith same operrating pressurre and temperrature.689 0.019 --0.04 0.002 0.707 0. Software and Systems Engineering Vol:10.154 0.018 --0.02 --0.4 3 441 0. 2016 waset.15 0.046 -0. MX ft.391 -1.inn.8@Node 60 440 0.048 0. 61 ProgDesignn VSH 4(SUS) 0 -226 0 0 0 0 15 Rigid +Y 2(SU US) 0 -13005 0 0 0 0 70 Rigid ANNC 4(SUS) 0 10 0 -1607 0 --643.102 1110 0.147 0.019 --0.019 --0.018 --0.391 -0.333 -0.101 1109 0.104  Piping Code:: B31. Industrial.018 --0.938 -1.0003 -0.8 B. Junee 29.0222 -0.082 0 0 0 0 1139 0. ft.5@Noode 50 551 0.078 0.021 --0.0119 -0.255 0. 2 is the International Scholarly and Scientific Research & Innovation 10(5) 2016 976 scholar. 10 0.1@N Node 60 449 -0.117 0. ft.587 -1.031 -0. In linear directiional 19 0.002 -0.232 0.) 339 0. Engineering and Technology International Journal of Mechanical.021 --0.158 0. R RZ deg.014 -0.034 0.078 0. normally thhe displacemeent will be hiigh and the stresss 220 0.208 -0.113 willl consider linnear direction of flow.018 --0. lb.0004 -0.005 0.lb.018 --0.018 --0.1226 -0.083  Allowable Sttress: 16600.034 -0.092 susttained load condition from CAESAR C II sooftware is detaailed 229 0.085  Code Stress:3451. Aerospace.111 willl apparently bee low.052 0.194 0.158 0.131 -0.org/Publication/10004702 442 0.083 1100 0. 330 0.llb..704 0.007 -0.002 0.025 0.098 1102 0.005 0. avaiilable namelyy thermal runn.056 0.651 0. Stress w will be more aat the flow wheere it 221 0.356 0.182 0. l FZ lb.253 0.253 0.105 1121 0 0.021 -0.019 --0.159 0.709 0.227 0.0002 -0.05 0.0 International Science Index.023 0.0008 -0.lb. DZ iin.907 -1. World Academy of Science.147 0.1@Nodde 22 448 0.089  Highest Stressses: (lb.066  Bending Streess: 2934.001 0 0.019 --0.021 --0.019 --0.028 770 0 0 0 0 0 0 999 0.667 0.046 -0. DY in.105 TA ABLE III Figg.001 0.045 0.056 0.068  Hoop Stress: 2602.315 -0.028 0.003 0 --0.329 -0.082 0 0 0 0 1131 0 0. No:5.105 1151 -0.033 -0.538 0.0222 -0.0222 -0.009 --0.109 is ddiverged into two t branches.051 0.CAE ESAR II S Support in CAEESAR II Softwarre OUTPUT F FX FY FZ MX MY MZ F Force / Load and a moment ata hanger locaations can alsso be N Node Loaad Case lb.15 0.

Code compliance evaluation for both the piping systems is passed i.004 0 0.005 -0.003 0 -0.013 -0.08 0.037 0.003 0 -0.301 -0.027 0.001 -0.122 direction of the pipe routing.007 0.003 0.001 0 0 0.12 developed is significantly reduced.002 0 0.004 0 0. DZin) and rotation IV. May 2013.042 -0.01 0.004 110 -0.007 119 0.317 0.001 -0.01 0. RY deg.002 Analysis of a Process Plant Piping System” International Journal of 58 0 0 0 0 0 0.012 -0.007 111 -0. 40 -0.042 -0. 2016 Nodal displacement (DXin.001 0 -0. Awze.004 thermal power plants” Head of Study and Research Division. From the TABLE V analysis it can be concluded that displacement in the piping LOAD AND MOMENT ON PIPING SYSTEM WITH EXPANSION JOINT AND systems with expansion joints are comparatively lower than RESTRAINTS SUPPORT . No.E “Introduction to piping engineer” suncum.037 0. M.006 -0.6.035 -0.002 0.037 -0.277 -0. Volume-2.003 0.001 0 0.002 [10] Intergraph CAESAR II® is a comprehensive and standard program for 60 0 0 0 0 0 0 Pipe Stress Analysis used worldwide.075 [3] D.027 -0.005 0.317 -0.005 0.001 -0. No:5.122 restraint is connected at the branches of the pipe routing.013 November.114 19 -0.009 0.003 0.033 -0.004 0 0.001 0 -0. No:5.007 121 0. 70 0 0 0 0 0 0 [11] M.007 When sustained type of loading is given to the piping system.01 0.031 -0.317 0.002 0 0 -0.01 0.084 [1] C.117 supports may lead to the complication of the pipe routing.037 -0.003 0 -0.004 0 -0.002 -0.01 0.org/Publication/10004702 21 -0.007 0 0 -0.069 Corporation.01 0. It is also observed that when a 11 -0. Industrial. Software and Systems Engineering Vol:10. Rajagopal.001 0 0.034 -0. RYdeg. International Science Index.005 0.1.002 -0.016 recent trends in engineering volume 1.037 0.002 -0. 59 0 0 0 0 0 0.043 -0. Oct 2000.01 0. World Academy of Science.003 0 -0.002 0. stress value was recorded with a ratio of 20.272 -0.007 [5] Shweta Bisht and Farheen Jahan “An Overview on Pipe Design using Caesar II” International Journal on Emerging Technologies Accepted 10 42 -0.102 reduced significantly.7% for piping system with hanger support and 20. 2016 waset. 38 -0.005 0. A. Balaji “Optimization of Piping Layout with Respect to Pressure and 30 -0.005 0. RZdeg) in all the three directions obtained The analytical study of piping system is done using the from the analysis of piping system using CAESAR-II software power piping code ASME 31.317 -0.019 span between pipe supports using maximum bending stress theory.8%.036 -0.028 0.01 0.005 -0.001 0. 31 -0.028 -0. Rev 0 “Hangers & Supports for Piping” Pipe Supports 99 0 -0.042 -0. [7] Aleksandar Jakovljevic “Stress analysis of high pressure steam lines in 49 0 0. P.001 0 0. stress 14 -0. DY in. May (2009) page 46-49.002 39 (2001) 153-165.001 0 0.02 0. 29 -0. Farooq A Determination of maximum 39 -0. Mohamed.035 -0.003 0.042 -0.006 -0.004 0 0. Vakharia.issue 3. 43 -0.317 0 0.045 -0.214).004 -0.CAESAR II OUTPUT the piping system with hangers. Mahalle “Design of Steam Pipe Layout and Hanger 33 -0.001 [8] Payal Sharma Ȧ*.002 0 0.284 0 0.003 0.01 0. Aerospace.027 [4] Dr. Hence an expansions joint Node DX in. 36 -0.1 and the piping system is are presented in Table V.001 0 0 0. plays a major role in decreasing the displacement in the linear 10 -0. 50 0 0.001 0 0 0 0 0.012 0.004 0 -0.1 cases is within the limits.007 131 0.004 0 0.8% for piping system with expansion joints and restraints.003 0. D.e. April 2014 [9] Gerald H.004 -0.01 0. Chapter B4.001 109 -0.042 Support in Thermal Power Station” International Journal of Recent Technology and Engineering (IJRTE) ISSN: 2277-3878.164 -0. The code stress ratio is 31.042 -0.002 Current Engineering and Technology .01 0. P.004 0 0.037 -0.317 0.292 -0. K.084 REFERENCES 26 -0.004 -0. Even though allowable stress in both the 20 -0.058 Temperature Using CAESER-II” ISSN: 2320-2491. International Scholarly and Scientific Research & Innovation 10(5) 2016 977 scholar.262 -0.Stress Analysis of Piping Systems.007 India Private Limited. DZ in. Maryland ASME journal. modeled and analyzed using CAESAR II platform. 100 -0.107–B.002 0.004 -0.001 101 -0. Engineering and Technology International Journal of Mechanical.317 -0.007 120 0.003 0 0. Mohit Tiwari Ȧ and Kamal Sharma Ȧ “Design and 51 0 0 0 0. DYin. Mechatronic and Manufacturing Engineering Vol:10.003 0 0.002 -0.CONCLUSION (RXdeg. the maximum stresses developed in the piping systems is less than the allowable stress mentioned by the process piping code ASME B 31.004 0 0.001 0 0.065 [2] M. Since more number of 15 -0.042 -0.002 0 0 -0.019 0. Basavaraju.072 -0.309 0 0.004 0 0.001 0 0.032 0. it is 17 -0.8/10004702 .037 -0.014 strengthened with advanced composites materials” thin walled structures 48 0 0.037 -0. Senior Engineering Specialist.001 0 -0.001 -0.037 0. Bechtel Power 28 -0.012 0. Page (B.042 Issue-2.001 0 0 -0.001 0. May.115 suggested to use expansion joints and displacements can be 18 -0.org/1999. RX deg.003 0 -0. 41 -0.316 0.093 23 -0.01 0.015 [6] Houssam Toutanji and Sean Dempsey “Stress modelling of pipelines 44 -0.waset. 2014. RZ deg.001 0 0.01 0.