An Overview of

Pipe Stress Engineering

Hà Long Vân
TPVN, HCMC, Nov 2015

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 Contents

1. General introduction
2. Fundamental knowledge
3. Applicable Codes and Standards
4. Interfaces
5. Workflow
6. Calculation tool
7. Deliverables

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 1. General introduction
Piping Stress Analysis is a term applied to calculations, which address the
static and dynamic loading resulting from effects of gravity, temperature,
pressure, fluid flow rate, wind and seismic activity

However, not only Stress !!

What is Stress ?

Force per Area unit

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 1. General introduction
The most important reason of Stress Analysis is SAFETY

How to judge piping design is SAFE ?

- Stresses are within allowed limits of applicable design codes
- Piping is supported adequately
- Piping deflections are within limits
- Safety of connected equipment and supporting structure
- Safety of piping components

How about COST ?

- Ensure optimize piping layout with minimum weld joints and fittings

Sufficient Flexibility

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 2. Fundamental knowledge
Engineering Stress-Strain curve
- Within linear area is elastic
behavior of ductile material

Ultimate - The value “E” is elastic modulus

stress and represent for stiffness of
material (slope line)

- As normal engineering practice,

we always want to design
material within elastic region

- Yield stress and Ultimate stress

are basis to define allowable
stress

https://en.wikipedia.org/wiki/Strength_of_materials#/media/File:Tension_test.svg
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 2. Fundamental knowledge
Stress-Strain curve at different temperature

With same test bar, same

apply load when temperature
increase:

- Stresses decrease: Yield

stress, Ultimate stress, etc.

- Elastic modulus decrease

 Stiffness decrease

http://911research.wtc7.net/mirrors/guardian2/wtc/WTC_apndxA.htm
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 2. Fundamental knowledge
Material at creep temperature

- Creep effect occurs when

permanent deformation of
material subjected to constant
stress

- Constant stress can be within

elastic region. It is basis to
define allowable stress

- Creep is of concern for:

CS above ~ 370 degC
SS above ~ 510 degC
Alloy above ~150 degC

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 2. Fundamental knowledge
Material under cycle condition – temperature expansion effect

Failure
A A

B Time

B C
- Failure occurs due to
micro cracks development
during cyclic loading

C - Stress can be within

elastic region

- Source of cyclic loading is

expansion and contraction
of material due to under
specific temperature
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 2. Fundamental knowledge
Material under cycle condition – temperature expansion effect
 
- Stress range  max Failure
N - Number of cycles to failure
 1  1
 2 Time
Endurance limit  min
 3


Failure
N  2
How to avoid fatigue failure? Time

1. Reduce stress range to endurance 

limit  reduce amplitude of Failure
 3
applied load Time
2. Design the material within a Common practice for
specific number of cycles to failure 20 years life of plant !
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 2. Fundamental knowledge
Thermal expansion of material ∆ = α x 10-6 x (Ope temp. – Basic temp.) x L
∆: thermal expansion of pipe (mm)
α: the mean coefficicent of linear thermal expansion
between Ope. temp. and Basic temp. (µm/m-oC)
(Ope temp. – Basic temp): temperature difference (oC)
Material: Carbon Steel
L: pipe length (mm)
Basic temp.: 21oC (70oF)
Operating temp.: 100oC (212oF)
L: 1000 mm

Note (2), ASME B31.3 2012, page 369:

“For Table C-3, multiply the value (µin./in.-°F)
by 1.80 to obtain the mean coefficient of linear
thermal expansion (µm/m-°C) between 21°C
and the given temperature”

 α (100oC) = 6.4 x 1.8 = 11.52 (µm/m-°C)

∆ = 11.52 x 10-6 x (100-21) x 1000 = 0.91 mm

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 2. Fundamental knowledge
Axial thermal force

What happend if we:

- Connect two equipments by a

straight line at high temperature

- Place two axial stoppers on a

straight line at high temperature

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 2. Fundamental knowledge
F = E x A x α x 10-6 x (Ope temp. – Basic temp.)
Axial thermal force
E: Modulus eleasticity of material (N/mm2)
A: Cross section area of pipe (mm2)
α: the mean coefficicent of linear thermal expansion between
Ope. temp. and Basic temp. (µm/m-oC)
(Ope temp. – Basic temp).: temperature difference (oC)

Pipe size: 6in - 168mm Schedule STD - 7.11mm

Material: Carbon Steel Basic temp.: 21oC (70oF)
Operating temp.: 100oC (212oF)
 E (21oC) = 29.5 x 106 (psi) = 203395 (N/mm2)
 A = 3595 (mm2)
 α (100oC) = 6.4 x 1.8 = 11.52 (µm/m-°C)

F = 203395 x 3595 x 11.52 x 10-6 x (100-21)

= 665455 (N) ≈ 67.9 (Ton)

What kind of EQP/Support

12 can stand against this force ?
 2. Fundamental knowledge
Axial thermal force

Structural beam Pipe support

Nozzle failure failure failure
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 2. Fundamental knowledge
Piping flexibility – Example 1

Material: A106B
Pipe size = 10’’
Thickness = 9.27mm
HOW TO REDUCE Temp. = 100oC
STOPPER FORCE? Length = 120000 mm
Stoppers at two ends

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 2. Fundamental knowledge
Piping flexibility – Example 1

Expansion loop
Height = 9000mm
Width = 8000mm

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 2. Fundamental knowledge
Piping flexibility – Example 2

Material: A106B
Pipe size = 14’’
Thickness = 9.53mm
Temp. = 250oC
Length 20-190 = 102000 mm
Length 240-260 = 48000 mm
Stopper at node 20,260 HOW TO REDUCE
Node 220 free to expand EXPANSION STRESS?

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 2. Fundamental knowledge
Piping flexibility – Example 2

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 2. Fundamental knowledge
Piping flexibility – Example 3

PSVs
Branch
connection

Expansion
loop

Expansion loop is required to:

- Avoid over stress at branch connection
- Avoid PSVs leakage

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 2. Fundamental knowledge
Piping flexibility

PIPING FLEXIBILITY MEANS

ADDITION OF ELBOWS/BENDS
INTO THE PIPING SYSTEM

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 2. Fundamental knowledge
Bases for design stresses - B31.3, 2012, para 302.3.2 (d)

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 2. Fundamental knowledge
Stress analysis classification CALCULATED STRESS < ALLOWABLE STRESS

Case Load Calculated Allowable Failure mode Meaning of

stress stress stress
Sustained 1. Dead weight SL Sh Collapse due to Limit value
+ Pipe over load
+ Insulation
+ Fluid
+ Valve
+ Flange
+ Bolt & Nut
+ Others
2. Pressure
Expansion 1. Temperature SE SA Collapse due to Limit range
(Flexibility) 2. Displacement cyclic loading
(Fatigue)
Occasional 1. Dead weight in S_OCC Factor * Sh Collapse due to Limit value
Sustained case over load
2. Wind
3. Seismic
4. Concentrate force

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 2. Fundamental knowledge
High stress locations
- Tee and Elbow will have high stress value
than straight pipe.

- They will be over stress if :

+ Piping layout is not enough flexibility
+ Placing support at incorrect location

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 3. Applicable Codes and Standards

What’s inside from stress view point?

- Allowable stress definition
- Code stress equations
- Pipe wall thickness calculation
- Material properties tables: Allowable
Stress, Modulus of Elasticity, Thermal
expansion coefficient, etc.
- Stress intensification factor

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 3. Applicable Codes and Standards

API 610 Centrifugal Pumps for Petroleum, Petrochemical & Natural Gas Industries
API 611 General Purpose Steam Turbines for Petroleum, Chemical, and Gas
Industry Service
API 616 Gas Turbines for the Petroleum, Chemical and Gas Industry Services
API 617 Axial and Centrifugal Compressors and Expander-compressors for
Petroleum, Chemical and Gas Industry Services
API 618 Reciprocating Compressors for Petroleum, Chemical & Gas Industry
Services
API 650 Welded Tanks for Oil Storage
API 661 Air Cooled Heat Exchangers for General Refinery Services
API 662 Plate Heat Exchangers for General Refinery Service
NEMA SM 23 Steam Turbine for Mechanical Drive Service
ASME SEC. VIII Rules for construction of Pressure Vessels

What’s inside from stress view point?

1. Allowable loads tables
2. Equipment evaluation procedure

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 Input required only

4. Interfaces Discipline: input required

Stress: special request

Discipline: input required

PROCESS CIVIL Stress: ouput required
Input: Input:
- P&ID - Structure design basis
- Line list - Structure displacment (Offshore PJ)
Request: - Settlement data
- Mark-up of cyclic - Soil data
operation mode Output:
- Slug/Surge data - Loading information

PIPING MECHANICAL
DESIGN
Input: Input:
- Stress sketch - EQP GA dwg
- 3D model - Nozzle allowable loads
- Material specification Output:
Output: - Loading information
- Critical line list Request:
- Stress marked-up P&ID - Nozzle flexibilities
- Piping movement - Nozzle load approval
- Recommendation
of flexibility SAFETY INSTRUMENT
- Rigid support type Input: Input:
and location - Surge analysis report - Weight of valves
- Spring support location - Blast analysis report - Weight of other instrument items
- Special pipe support - PSV data sheet
concept
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 5. Workflow

Sketch Submit Calculation

submit Stress calculation Stress package Center
Piping
Designer Engineer Checker Filling

Sketch with:
- Modification of piping rout
Sketch request
- Support type
Mark-up P&ID
- Piping displacement
Sketch with - Loading data for Civil/Equipment
mark up of
layout change
Stress Piping
Engineer Designer

Update
P&ID
3D model
Line List

Process PDS/PDMS
Engineer Operator

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 6. Calculation tool
CAESAR II
Analysis method : Finite element method

Element type : 3D Beam Element

Model : A system of 3D Beam elements

Analyze : F = KX
F – External loads
K – Stiffness of the model
X – Displacement

Evaluate : Check the design limits

- Stress
- Equipment nozzle loads
- Pipe support loads
- Pipe displacements

Since the design ASME codes are revised year by year,

the appropriate software version shall be applied.

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 6. Calculation tool

Stress summary

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 6. Calculation tool

Nozzle loads

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 6. Calculation tool

Support loads

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 6. Calculation tool

Displacements

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 6. Calculation tool

3d plot

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 7. Deliverables

1. Critical line list

2. Stress analysis specification
3. Technical specification/Data sheet:
- Spring support
- Sliding plate
- Strut
- Expansion joint
4. Stress analysis report

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Questions ?