Modeling and Stress Analysis of Pump Piping

IOP Conference Series: Materials Science and Engineering
PAPER • OPEN ACCESS
Modeling and Stress Analysis of Pump Piping

To cite this article: N. Prabhu Kishore and S. Prabhu 2018 IOP Conf. Ser.: Mater. Sci. Eng. 455 012100
View the article online for updates and enhancements.
This content was downloaded from IP address 181.214.208.252 on 20/12/2018 at 01:05

ICAAMM IOP Publishing
IOP Conf. Series: Materials Science and Engineering 455 (2018) 012100 doi:10.1088/1757-899X/455/1/012100
MODELING AND STRESS ANALYSIS OF PUMP PIPING
N.Prabhu Kishore 1, S.Prabhu2

1 Associate professor, Department of Mechanical Engineering, MLR Institute of
Technology, Hyderabad.
2 MTech Scholar, MLR Institute of Technology, Dundigal, Hyderabad.
Email: prabhupatil84@gmail.com , prabhunutakki@gmail.com
Abstract: Every process piping industry uses several pumps in each process unit. Sometimes the
analysis is very critical. This article e xpla ins about elaborate the method followed for stress
analysis of a pump piping system. The stress system consists of typical discharge and suction lines
of two pumps. Fluid from the tank is pumped to another. As per P&ID only one pump will operate
at a time, other pump will be a stand by pump. This article exp lains about the stress analysis
methodology in three parts: - a) Modeling of Pump b) Preparation of analysis Load cases and c)
analyzing the output results. Externa l loads imposed by piping on rotating equipment nozzle
should be less than allowed loads. If e xcessive loads are imposed, misalignment may result that
affects mechanical operation and could cause objectionable vibration. A close alignment between
rotating and stationary parts must be maintained. The provision for e xpansion of the casing and
maintaining close clearances requires that the forces and moments due to the piping are limited.
The API 610 standard gives equation to calculate allowable forces and moments in the case of
pumps for general refinery service. The criteria apply for pumps with 4 Inches discharge nozzles
or smaller (suction nozzle may be larger) and situations where the pump is constructed of steel or
alloy steel. The modulus of elasticity of the piping material at operating temperature (known as ho t
modulus) can be used to calculate actual loads. Using hot modulus will result in lower loads
because the piping is more flexible at higher temperature. This paper is designed for studying a
wide range of abilities and backgrounds this will cover the fundamental principles, concepts used in
pipe stress analysis.
1. INTRODUCTION
Piping system is the artery of fluid transportation to the pant. For safe operation, design of piping system
plays major role in safeguard of entire assets which require detailed engineering and analysis.
To perform detailed engineering the plant requires the plan to develop the routing feasibility and that
routing shall be stress freed as the piping fluid with pressure and temperature.
This piping routing shall be carried out with the help of scheme and Piping & Instrumentation Diagrams
(P&ID).
The purpose of this paper is to design and finalizing the piping routing of Pump suction and discharge.
The software CAESER-II is used to check the piping system’s flexibility to find within the stress limits of
acceptable codes and standards.
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Published under licence by IOP Publishing Ltd 1
Piping stress analysis is an important study where the material behavior is analyzed with pressure /
thermal effects of travelling fluid and when where reaction of piping supports and nozzle terminals are
shall be evaluated to the designed limits.
2. Execution of piping stress analysis:
a. Preparation of critical piping line list:

In a process complex, the piping networks are segregated into their working process conditions.
The criticality of the piping system is studied by its operation of fluid pressure, temperature,
velocity, density, pipe size & schedule, material class etc. with all these parameters
system/network wise list prepared and issued as input for the system analysis.
b. Documents Required:
For analysis to execute in Caesar-II software following inputs are required, P&ID, Critical line
list, Piping Isometrics with support feasibilities, Equipment/vendor drawings (Eg. For pump
system: Pump vendor drawings & applicable codes like API-610, Tank General Arrangement
drawing & applicable code API-650), project piping support standard, ASME-31.3 code
requirements, etc.
c. Pipe Stress Analysis Software:

In oil and gas, power industries there are approved software’s to assess piping flexibilities like
CAESAR-II (Computer Aided Engineering and Stress Analysis Reviewer), Auto Pipe, Nozzle
pro& FEA (Finite Element Analysis), CAEPIPE etc.
For this study report we used CAESAR-II software which widely used to check the piping
flexibility.
Input/model the piping network in Caesar-II, put appropriate support as per requirement, analyze
the system, where required use the piping loops and change in direction to absorb the thermal
expansion, review the displacements, piping support loads, check the stress limits as applicable
and report the assessment.
Figure1: Operational Graph
2
The following summary to design piping flexibility:
¾ Study to route the piping with support feasibility and access for operation as per P&ID.
¾ Provide the adequate piping support and with acceptable span to prevent excessive sagging.
¾ Provide sufficient flexibility for piping to absorb thermal expansion or contraction to safeguard
and to prevent excessive stress at piping or at equipment nozzles.
¾ Once the piping qualified in all aspects of design, isometrics are issued to construction.
a) To keep the stresses in the pipes and fittings within the code allowable levels.
b) To keep the nozzle loadings on the attached equipment within allowable limits of applicable
specifications or recognized standards (NEMA, SM23, API 610, API 661, etc.)
c) To minimize vibration of the reciprocating compressor associated piping.
d) To calculate the design loads for sizing of in-line restraints such as U-bolt, Shoe, Clamp, Trunnion,
Guide, Stop, etc., sizing of support frames and selection of spring hangers.
e) To determine the piping displacements for interference check and prevent excessive sag in piping
spans.
f) To check the leakage at the flange joints.
g) To prevent unintentional disengagement of piping from its supports.
h) To help optimize the piping design.
3. Codes and Standards:

Design and analysis of the piping shall be in accordance with following codes.
3
4. PROCEDURE OF ANALYSIS
STRESS ANALYSIS FLOW CHART

Preparation of Critical Line List
Documents(Isometrics)
Pipe Stress Analysis(Software)
Inputs in the Software
Run,Checking the Errors & Warnings
Analysis(Stress,Loads,Displacement)
Generating Reports
Figure2 Flow chart of stress analysis
4
Table1. Pump process data sheet:
Table2.Process Critical Line List:
FLUI D FLUI D TEST NDT
SRNO REV P& id N O SEQ SIZ E FLUI D PIPING P & id N O LIN EN O PRESS URE TEMP PRESS URE TEMP STR ESS STR ESS ANA LYSIS DEN SI TY PHASE PRESSM
UR
EDE IU M PWHT RT MT OR L T VISUA L PAINTING AREA REMARKS
NO NO NPS CODE CLASS BARG DEG C
60 1 0007 211 6 HC A2 CSN ZP- 50- PR- 25- 0007 211 -6"- HC- A2 CSN ATM 30 0 .1 - 29 /8 Y SYS- 012 74 LIQ UID 3H N 10 10 (**) 100 CS- 1 BOP
65 1 0008 212 4 HC A2 CSN ZP- 50- PR- 25- 0008 211 -4"- HC- A2 CSN 3 30 0 .1 - 29 /8 Y SYS- 012 74 LIQ UID 15 H N 10 10 (**) 100 CS- 1 BOP
66 1 0008 213 5 HC A2 CSN ZP- 50- PR- 25- 0008 211 -2"- HC- A2 CSN 3 30 0 .1 - 29 /8 Y SYS- 012 74 LIQ UID 3H N 10 10 (**) 100 CS- 1 BOP
67 1 0008 214 4 HC A2 CSN ZP- 50- PR- 25- 0008 211 -4"- HC- A2 CSN ATM 30 0 .1 - 29 /8 Y SYS- 012 74 LIQ UID 15 H N 10 10 (**) 100 CS- 1 BOP
68 1 0008 229 4 HC A2 CSN ZP- 50- PR- 25- 0008 211 -4"- HC- A2 CSN 3 30 0 .1 - 29 /8 N SYS- 012 74 LIQ UID 15 H N 10 10 (**) 100 CS- 1 BOP
70 1 0008 223 6 HC A2 CSN ZP- 50- PR- 25- 0008 211 -6"- HC- A2 CSN ATM 30 0 .1 - 29 /8 Y SYS- 012 74 LIQ UID 3H N 10 10 (**) 100 CS- 1 BOP
71 1 0008 224 4 HC A2 CSN ZP- 50- PR- 25- 0008 211 -4"- HC- A2 CSN 3 30 0 .1 - 29 /8 Y SYS- 012 74 LIQ UID 15 H N 10 10 (**) 100 CS- 1 BOP
5
FIGURE 3. Stress Isometric with Nodes
FIGURE 4. Caesar-II Model
5. LISTING OF STATIC LOAD CASES FOR PUMP PIPING (SUCTION AND DISCHARGE)
ANALYSIS:
6
6. RESULTS:
7
{ TC."Stress.Summary; Multiple" /f C}LOAD CASE DEFINITION KEY

CASE 1 (HYD) W\V+HP
CASE 8 (SUS) W+Pl
CASE 25 (OCC) L25=Ll 7+L8
CASE 26 (OCC) L26=Ll 8+L8
CASE 27 (OCC) L27=L19+L8
CASE 31 (OCC) L3l =L23+L8
CASE 33 (EXP) L33=L2-L8
CASE 37 (EXP) L37=L33+L35
Piping Code: B3l .3 = B3l .3 -2008, December 31, 2008
CODE STRESS CHECK PASSED : LOADCASE 1 (HYD) WW+HP

Highes t Stresses: (NJ sq.mm. ) LOADCASE 1 (HYD) WW+HP
Code Stress Ratio (%): 18.3 @Node 5060
Code Stress: 44.1 Allowable: 241.3
Axial Stress: 44.1 @Node 5060
Bending Stress: 15.3 @Node 15120
Torsion Stress: 6.3 @Node 15180
Hoop Stress: 88.3 @Node 5047
3D Max Intensity: 88.7 @Node 5047
CODE STRESS CHECK PASSED : LOADCASE 8 (SUS) W+Pl

Highes t Stresses: (NJ sq.mm. ) LOADCASE 8 (SUS) W+Pl
CODE STRESS CHECK PASSED : LOADCASE 25 (OCC) L25=Ll 7+L8
Highes t Stresses: (NJ sq.mm. ) LOADCASE 25 (OCC) L25=Ll 7+L8
8
CODESTRESS CHECK PASSED : LOADCASE 26 (OCC) L26=L18+L8

Highes t Stresses: (NJ sq.mm. ) LOADCASE 26 (OCC) L26=L18+L8
CODE STRESS CHECK PASSED : LOADCASE 27 (OCC) L27=L19+L8



9

CODE STRESS CHECK PASSED : LOADCASE 31 (OCC) L3l =L23+L8

Highes t Stresses: (NJ sq.mm. ) LOADCASE 31 (OCC) L3l =L23+L8

CODE STRESS CHECK PASSED : LOADCASE 33 (EXP) L33=L2-L8

Highes t Stresses: (NJ sq.mm. ) LOADCASE 33 (EXP) L33=L2-L8
10


code Stress Ratio (%): 6.8 @Node 10706

CodeStress Ratio (%): 2.4 @Node 15670
CODE STRESS CHECK PASSED : LOADCASE 37 (EXP) L37=L33+L35

Highes t Stresses: (NJ sq.mm. ) LOADCASE 37 (EXP) L37=L33+L35
11
Table 3. LOAD CAS ES AT NODE 10560
LOAD MX MY MZ
DY.mm
NODE CASE FX N FY N FZ N N.m N.m N.m DX.mm DZ.mm
16(OPE) 0 -985 0 0 0 0 0.078 -0.000 0.243
- - -
MAX 620/L14 1696/L4 -507/L4 3.000/L13 0.000/L4 1.596/LS
RIGIT +
10560 Y
1(HYD) 163 -2201 -46 0 0 0 0.001 -0.000 0.000
2(OPE) -189 -1767 495 0 0 0 -0.377 -0.000 0.989
3(OPE) -150 -3082 912 0 0 0 -0.022 -0.000 0.131
4(OPE) 0 0 0 0 0 0 0.305 0.227 -0.718
5(OPE) 0 -2751 0 0 0 0 -0.324 -0.000 0.132
6(OPE) -181 -3114 916 0 0 0 -0.026 -0.000 0.131
7(OPE) -176 -2625 768 0 0 0 -0.016 -0.000 0.068
8(OPE) 156 -2138 -41 0 0 0 0.001 -0.000 0.000
9(OPE) 403 -2755 722 0 0 0 0.073 -0.000 0.132
10(OPE) -666 -2932 574 0 0 0 -0.153 -0.000 0.132
11(OPE) -126 -2889 857 0 0 0 -0.019 -0.000 0.132
12(OPE) -183 -3291 970 0 0 0 -0.025 -0.000 0.131
13(OPE) 0 -2661 0 0 0 0 2.716 -0.000 0.132
14(OPE) 0 -2819 0 0 0 0 -2.841 -0.000 0.132
15(OPE) 0 -2710 0 0 0 0 -0.645 -0.000 0.133
16(OPE) 0 -2791 0 0 0 0 -0.004 -0.000 0.132
- - -
0.227/L4
MAX 666/L10 329/L12 970/L12 2.841/L/14 0.989/L2
12
Table 4. FORCES AND MOMENTS @ PUMP NOZZLE-DN1(2”) 12280 NODE
Table 7. FORCES AND MOMENTS @ VESS EL NOZZLE-N2(3”) 5025 NODE
13
7. CONCLUSION:
Stress Analysis of pump piping system between pump and vessel is made as safe by providing an
expansion loop. As per ASME 31.3. Pump and Vessel nozzles are within theAllowable Stress, Nozzle
loads, Restraint loads, all are within the limit after providing an expansion loop as per Standards.
REFERENCES
[1]. G.A. Antaki, Piping & Pipeline Engineering: Design Construction, Maintenance, Integrity & Repair,
CRC Press, 2003.
[2]. Roy A. Parisher, Pipe Drafting & Design, Gulf Professional Publishing, 01- Jan- 2012-07-29.
[3].Mohinder L. Nayyar, Piping Hand book, McGraw Hill, seventh edition 2000.
[4]. LANL Engineering Standards Manual PD342, ASME B31.3, 2004 –Edition
[5].J. Okrajni, K. Mutwil and M. Cieoela, Chemical pipelines material fatigue, Departments of Mechanics
Of Materials, Silesian University of Technology, Poland.
[6].HoussamToutanji, Sean Dempse, Stress modeling of pipelines strengthened with advanced composites
materials, Thin-Walled Structures, Volume 39, Issue 2, February 2001, Pages 153-165.
[7]. Sam Kannapan, Introduction to Pipe Stress Analysis, Pages 123-125.
14

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IOP Conference Series: Materials Science and Engineering

PAPER • OPEN ACCESS

Modeling and Stress Analysis of Pump Piping

View the article online for updates and enhancements.

This content was downloaded from IP address 181.214.208.252 on 20/12/2018 at 01:05

MODELING AND STRESS ANALYSIS OF PUMP PIPING

N.Prabhu Kishore 1, S.Prabhu2

2. Execution of piping stress analysis:

a. Preparation of critical piping line list:

c. Pipe Stress Analysis Software:

Figure1: Operational Graph

The following summary to design piping flexibility:

3. Codes and Standards:

STRESS ANALYSIS FLOW CHART

Pipe Stress Analysis(Software)

Inputs in the Software

Run,Checking the Errors & Warnings

Figure2 Flow chart of stress analysis

Table1. Pump process data sheet:

Table2.Process Critical Line List:

FLUI D FLUI D TEST NDT

NO NO NPS CODE CLASS BARG DEG C

FIGURE 3. Stress Isometric with Nodes

FIGURE 4. Caesar-II Model

{ TC."Stress.Summary; Multiple" /f C}LOAD CASE DEFINITION KEY

Piping Code: B3l .3 = B3l .3 -2008, December 31, 2008

CODE STRESS CHECK PASSED : LOADCASE 1 (HYD) WW+HP

CODE STRESS CHECK PASSED : LOADCASE 8 (SUS) W+Pl

CODESTRESS CHECK PASSED : LOADCASE 26 (OCC) L26=L18+L8

CODE STRESS CHECK PASSED : LOADCASE 27 (OCC) L27=L19+L8

CODE STRESS CHECK PASSED : LOADCASE 28 (OCC) L28=L20+L8

CODE STRESS CHECK PASSED : LOADCASE 29 (OCC) L29=L21+L8

CODE STRESS CHECK PASSED : LOADCASE 30 (OCC) L30=L22+L8

CODE STRESS CHECK PASSED : LOADCASE 31 (OCC) L3l =L23+L8

CODE STRESS CHECK PASSED : LOADCASE 32 (OCC) L32=L24+L8

CODE STRESS CHECK PASSED : LOADCASE 33 (EXP) L33=L2-L8

CODE STRESS CHECK PASSED : LOADCASE 34 (EXP) L34=L3-L8

CODE STRESS CHECK PASSED : LOADCASE 35 (EXP) L35=L4-L8

CODE STRESS CHECK PASSED : LOADCASE 36 (EXP) L36=L5-L8

CODE STRESS CHECK PASSED : LOADCASE 37 (EXP) L37=L33+L35

Table 3. LOAD CAS ES AT NODE 10560

Table 4. FORCES AND MOMENTS @ PUMP NOZZLE-DN1(2”) 12280 NODE

Table 5. FORCES AND MOMENTS @ PUMP NOZZLE-DN1(3”) 10820 NODE

Table 6. FORCES AND MOMENTS @ PUMP NOZZLE-DN1(3”) 11280 NODE

Table 7. FORCES AND MOMENTS @ VESS EL NOZZLE-N2(3”) 5025 NODE

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