PIPE STRESS ANALYSIS: AN INTRODUCTION

FDC- PIPING REAL JAMNAGAR, GUJARAT, INDIA.

v

Refinery & Petrochemical (e.g. Reliance Jamnagar Refinery)

CES

CTS

Lab

Admin

FDC

O&M

Procr & Contrc

Safety

Process

Mech

Proj

Piping

Elect

Civil

Const

Piping layout Design Grp.

Pipe Stress Analysis: Reliability Engg. Grp.

(Not exhaustive)

BG/EIPSRE/REAL/310305

2

Let Us Start: Milestones
•Introduction •Milestones •Piping Design & its Reliability Concern

•Pipe Stress Analysis - I: Loads on Piping System
•Pipe Stress Analysis - II: Stresses on Piping System
•Pipe Stress Analysis – III: What are Stressed on Stress Analysis •Pipe Stress Analysis – IV: The Governing Codes •Pipe Stress Analysis – V: How Things Are Carried Out •Pipe Stress Analysis – VI: Interactions With Other Departments •Pipe Stress Analysis – VII: Few Technical Aspects

•Pipe Stress Analysis – VIII: Roles of The Analyst
•Pipe Stress Analysis – IX: Associated Instructions & Design guide/spec. •Conclusions & Q-A Session.
BG/PSAIntro/REAL/290605 3

Piping Design & Its Main Concerns
 Techno-Commercial Concern.  Reliability Concern: Pipe-Stress-Analysis

 Future Expansion Provisions.

BG/EIPSRE/REAL/310305

4

Reliability Concerns of Piping Design
 Pipe & Piping System.  Pipe Stress.  Stress analysis.  Adding Flexibility/ Rigidity & Proper

Supporting.

BG/EIPSRE/REAL/310305

5

Pipe Stress Analysis – I Loads On Piping System

Back To School: Stress – Strain
Relationship.

Loads on the Piping System:
*Primary Vs. Secondary *Static Vs. Dynamic
BG/EIPSRE/REAL/310305 6

BG/EIPSRE/REAL/310305

7

Thermally deflected Upward at Elevated Temperature

The actual Pipe

Example of Secondary Loading: Thermal strain

BG/EIPSRE/REAL/310305

8

Actual Pipe

Deflection Under Weight & Sustained Loading: Primary Loads

BG/EIPSRE/REAL/310305

9

Pipe Stress Analysis – II Stresses on Piping System
 Primary Stresses: Axial stress, Longitudinal stress due to internal pressure, Bending stress due to Uniform/Concentrated loading, Hoop stress, Shear stress etc.  Secondary Stresses: Thermal Expansion stress, stress due to Vibration, Fatigue stress due to long cycles, Time dependent stress like Creep etc.
BG/EIPSRE/REAL/310305 10

Pipe Stress Analysis– III
What are Stressed on Stress Analysis

Complying with Governing Codes. Safety for Connected Equipment & Supporting
Structures.

Acceptability of Piping Displacement.
Stability of Piping system under Dynamic Loads.
BG/EIPSRE/REAL/310305 11

Pipe stress Analysis - IV The Governing Codes ASME B31.1: Power Piping Code ASME B31.3: Process piping Code ASME B31.4: Oil Transportation Piping Code ASME B31.8: Gas Transportation Piping Code
There are Standards like ASTM, API, NEMA, EJMA etc.
(Not Exhaustive)

BG/EIPSRE/REAL/310305

12

Pipe Stress Analysis - V How Things Are Carried Out

 Inputs:
~ Process: P&ID & LDT (Through PDS). ~ Layout Group: Isometrics. ~ Mechanical: Equipment GA & datasheets. ~ Civil: Soil Characteristics
BG/EIPSRE/REAL/310305 13

Pipe Stress Analysis– V
How Things Are Carried Out
Processing: ~Modeling ~Simulating the actual behavior. ~Computing results using a Core Solver of Simulating S/w CAESAR-II, 4.5v, a product of COADE, INC, USA.
BG/EIPSRE/REAL/310305 14

Pipe Stress Analysis– V
How Things Are Carried Out

Output:
~Interpretation of Computer generated output. ~Flexibility Considerations ~Load & Displacement consideration at nozzles & supports. In all Operating, Upset & Occasional cases. Formal Stress Analysis Report generation & submission.
BG/EIPSRE/REAL/310305 15

Pipe Stress Analysis – V How Things Are Carried Out General Contents of Formal Stress Analysis Report:  SATS Front Sheet, Title Sheets (Design Basis)  Stress Check List – I & II  Load Summary Chart & Restraint Report  Displacement Report, Hanger Report  Hanger Datasheets, Special Pipe Support reports  Caesar Dump, Marked up Isometrics  Equipment G/A drawing & Datasheets  P&ID, LDT.
BG/EIPSRE/REAL/310305 16

Stress Team Interactions with Other Departments - VI
Process Dept.

Instrumentation Dept.
Instrument data

P&ID LDT

Fabrication and Erection Isometric

Piping Team
Supports Loadings for pipe support selection, pipe displacements at operating temp.

Site/ Field
Spring, SPS, Specials data sheets, Site problem resolutions, Audit Reports

Civil Dept.

SAQ, alongwith Stress Isometrics and other data

Mechanical Dept.

Stress Analysis Team
Soil Characteristics Equipment G.A.'s

Civil and Structural Support loadings

Stress Analysis Report BG/EIPSRE/REAL/310305

Cleat Loads, Nozzle loads if more than allowables

17

Pipe Stress Analysis– VII
Few Technical Aspects
Flexibility Vs. Rigidity of a Piping system. Expansion Loops, expansion joints etc. Hanger Supports, Supports from Structures & equipments. Pipe Guides, Line Stops, Anchors etc Trunion.
BG/EIPSRE/REAL/310305 18

Pipe Stress Analysis– VIII
Roles of The Analyst
Carrying out the Analysis, releasing Report, carrying out
proper documentation for the analysis. Transferring the load values to Piping layout Designer for passing on to other dept. Storing the final stress reports, any other reference calculations, audit files, Caesar soft copies at proper locations and retrieving the latest files as & when needed. Issuing & storing drawings & datasheets of spring, SPS, snubbers etc. NOTE: This is a general simplified list. For actual details refer to the various PL series of documents as listed below.
BG/EIPSRE/REAL/310305 19

Associated Instructions & Design Guides/ Specifications
P-SS-PL-001:Piping Material Spec. P-SS-PL-093:Stress Analysis Work Procedures. P-SS-PL-003:Piping Design & Plant Layout. P-SS-PL-008:Pipe Stress Analysis. P-PS-PL-009:Pipe Stress Critical line List. P-SS-PL-015:Pipe Supports. P-EP-PL-060:Documentation Procedure for Springs, SPS, Snubbers etc. P-EP-PL-087/88:Support/Spring Audit Procedure.
BG/EIPSRE/REAL/310305
20

Conclusion

 Summary.  Benefits to the Organization

BG/EIPSRE/REAL/310305

21

“ Thank You Very Much”
 …Welcome

to Your Queries !!

For any further queries:  bhaskaram_gangopadhyay@ril.com  0288-3010951
BG/EIPSRE/REAL/310305 22

BG/EIPSRE/REAL/310305

23

BG/EIPSRE/REAL/310305

24

BG/EIPSRE/REAL/310305

25

BG/EIPSRE/REAL/310305

26

BG/EIPSRE/REAL/310305

27

BG/EIPSRE/REAL/310305

28

BG/EIPSRE/REAL/310305

29

BG/EIPSRE/REAL/310305

30

BG/EIPSRE/REAL/310305

31

BG/EIPSRE/REAL/310305

32

Fillet weld to high temperature line

At ambient temperature

Effect of Temperature gradient: Differential thermal growth at top & bottom of saddle causing tremendous shear force on the weld. In long term crack is obvious to generate & propagate to the extent of failure.

BG/EIPSRE/REAL/310305

33

BG/EIPSRE/REAL/310305

34