Basic Input & Modeling

 Why Stress analysis using software?

 Optimization
 To save time
 To save cost
 Get best result
CONTENT:-
I. PART ONE

1. Basic Input Data

2. Equipment Modeling
3. Equipment nozzle displacement
4. Skirt equivalent temp
5. Trunnion Modeling
6. Expansion Joint selection
7. Buried Piping modeler
8. Outgoing data from stress team to layout and
other dept.
II. PART TWO
1. Spring selection & modeling
2. Wind analysis
3. Seismic analysis
1. Basic Data

1) From layout team

2) From Civil
3) From Mechanical
4) From Process
5) From Instrument
6) From Material
From layout team

1) Stress Isometrics with proper north

marking
2) Support location either standard or
special arrangement
3) Confirm whether which support from
equip. or separate structure
4) Space availability for Spring Hanger or
Rigid rod Hanger
5) Support feasibility check for newly added
support
From Civil

1) Site Spectra for Seismic analysis

2) Soil properties for buried piping analysis
3) Foundation settlement data:-
a) Large capacity floating roof storage

tanks
b) Differential settlement bet. Pile & Shallow
foundation
c) Load bearing capacity for very critical
piping supports carrying severe piping loads
Site spectra
From Mechanical

1) Nozzle displacements (Thermal/Wind sway)

2) Equipment vendor drawings includes:-
a) nozzle thermal movement & allowable
b) Tower skirt opening support detail
c) Nozzle neck thickness
d) Special nozzle arrangement (skewed/
Tangential)
e) Metal temp. at different condition
f) Cross verification of fixed/sliding side
H.E. w.r.t. North

g) Any other upset conditions

From Process

1) Process line list

2) P & ID
3) Regeneration Process
4) Process data sheet of equipments
5) Temp profile for flare headers, columns
6) Any Critical/upset conditions
7) Fluid category (D/M) for expansion joint
usage
P & ID
Regeneration process
From Instrument

1) Process data sheet for PSV & Vendor

drawing
2) Control valve drawing with actuator
weight/ whole assembly weight
3) Other instrument weight i.e. Flow
element
Form Material

1) Piping Material Specification

2) Weight of specialty item
2. Equipment Modeling
1) Column
2) Vessel (skirt/ leg supported)
3) H.E. Horizontal (with bellow) fixed tube sheet
4) H.E. horizontal (without bellow) fixed &
floating tube sheet
5) H.E. vertical
6) Reboiler
7) Stacked H.E.
8) Storage tank
9) Air fin cooler (odd/ even pass)
10) Centrifugal pump (fixed point at center/base)
11) Silencer
12) Heater (Radiant zone/ Convection zone)
1) Column
2) Vessel (Skirt supported)
2) Vessel (Leg supported)
3) H.E. Horizontal (with bellow) fixed tube
sheet
4) H.E. horizontal (without bellow) fixed
tube sheet
5) Stacked H.E.
6) Reboiler
Reboiler Data Sheet
7) Storage tank
8) Turbine and Compressor
9) Centrifugal pump (fixed point at
center/base)
10). Silencer
10). Silencer
10). Silencer
11)Heater (Radiant zone/ Convection zone)
12) Air-fin cooler (Odd pass)
Air-fin cooler (Even pass)
3. Equipment Nozzle Displacement

1) Compressor & Turbine

2) Air fin cooler
3) Heater
4) Cold box
5) Storage tank
 4. Skirt equivalent temp. calculation

CALCULATIONS FOR SKIRT EXPANSION :-

The following formula is used to calculate the average temperature of skirt
ΔT = T - 70
ΔT’ = F x ΔT
T’ = ΔT’+ 70 (°F)
Where,
T’ = Average temperature of skirt (°F)
T = Temperature at the top of skirt (°F)
F = to be calculated from graph
Calculations for “F” from graph :
Calculate value of k* h / (t)^0.5
K=1 for skirt fully insulated
K=1.7 for skirt fire-brick insulated
K=2.7 for skirt not insulated
kh
t
f

0 1
2 0.8
4 0.54
6 0.38
8 0.28
10 0.22
12 0.18
14 0.16
16 0.14
18 0.12
20 0.11
22 0.1
24 0.09
26 0.08
28 0.08
30 0.08
32 0.08
34 0.08
5. Trunnion modeling
 6. Basic of Expansion Joints
What are expansion joints?

They are devices containing

one or more metal bellows
used to absorb dimensional
changes such as those
caused by thermal expansion
or contraction of a pipe-line, Bellows
Bellows
duct or vessel.
 Where to use?
 Space limitation, compact length
 Isolate the strain sensitive equipment
from undue reactions
Basic Expansion Joints

Bellows Components

• Regardless of the
manufacturing method
used, all bellows consist
of the same basic
components.
Design Variables

• Size/Diameter - Refers to the diameter of the connecting pipe

• Movement - Axial, Lateral and Angular Rotation
• Pressure - Minimum and maximum pressure requirements
• Temperature - Minimum and maximum operating temperature
• Flowing Medium - The substances that the expansion joint will
come in contact with
• Overall Length - Maximum/minimum length of expansion joint
Design Variables

Lateral deflection, or
• Movement - Axial, Lateral offset, is motion
which occurs
and Angular Rotation perpendicular or at
right angles to the
centerline of the
bellows.
Axial movement
is motion
occurring parallel
to the center line
of the bellow and
can be either
extension or Angular Rotation is
compression the bending of an
expansion joint
along its centerline.
 Design Variables

• Movement – Torsional Motion

Torsional movement is the rotation
about the axis through the center of
a bellows (twisting). Torsion
destabilizes an expansion joint
reducing its ability to contain
pressure and absorb movement. If
torsion is present in a piping
system, hinges, slotted hinges or
gimbals are recommended to
combat the torsion.
Design Variables

• Pressure - Minimum and maximum

pressure requirements.
Pressure is possibly the most important
factor determining the design of an
expansion joint.
Care should be exercised to insure that
these specified pressures are not
increased by unreasonable safety
factors.
Design Variables

• Temperature - Minimum and

maximum operating temperature

Temperature will affect the

expansion joints pressure
capacity, allowable stresses, cycle
life and material requirements.
Expansion joints can range from
-325°F up to 2,500°F
Design Variables

• Flowing Medium - The

substances that the expansion
joint will come in contact with.

In some cases, due to excessive

erosion or corrosion potential, or
in some cases of high viscosity,
special materials should be
specified.
Expansion Joint Accessories
Flange
• End Connections & Accessories Bellows
The basic unit of every expansion
joint is the bellows. By adding
additional components, expansion
joints of increasing complexity
and capability are created which
are suitable for a wide range of
applications. Tie
Rods

Shipping
Bars Cover
Expansion Joint Accessories

• Protective Covers & Liners

Cover-A device used to
provide external protection to
the bellows.

Liner- A device which minimizes

the effect on the inner surface of
the bellows by the media flowing
through it.
Expansion Joint Accessories

• Restraints
Tie Rods-Ties rods are devices, usually
in the form of bars or rods,attached to
the expansion joint assembly and are
designed to absorb pressure loads and
other extraneous forces like dead weight
Limit Rods- Limit rods are used to
protect the bellows from movements in
excess of design that occasionally occurs
due to plant malfunction or the failure of
an anchor.
Expansion Joint Accessories

• Purge Connectors
Purge Connectors-Purge connections
are used in conjunction with internal
liners to lower the skin temperature of
the bellows in high temperature
applications such as catalytic cracker
bellows. The purge media can be air or
steam which helps flush out particulate
matter between bellows and the liner.
This also prevents the build up of harmful
solids in the convolutions that may stop
the bellows from performing.
Types of Expansion Joints

• Unrestrained Type
Assemblies not capable of restraining the
pressure thrust of the system. The pressure
thrust must be contained using main anchors
or equipment.

 Single
 Universal
 Externally Pressurized
Types of Expansion Joints

• Restrained Type
The expansion joint hardware is capable of
restraining the pressure thrust of the system.
Intermediate anchors are required to
withstand the spring force generated when
the expansion joint is deflected. The need for
main anchors is eliminated.
 Tied Single Bellows Assemblies
 Tied Universal Assemblies
 Hinged & Gimbal Bellows Assemblies
 Pressure Balanced Assemblies
Types of Expansion Joints

• Restrained Type – Tied Assemblies

 Tied Single Bellows Assemblies add
tied rods to a Single Bellows Assembly
to increase design flexibility in a piping
system. The tie rods are attached to the
pipe or flange with lugs that carry the
pressure thrust of the system, eliminating
the need for main anchors.
 Tied Universal Assemblies are similar
in construction to a Universal Assembly
except that tie rods absorb pressure thrust
and limit movements to lateral offset and
angulations only.
Types of Expansion Joints

• Restrained Type – Hinged & Gimbal

 Hinged Bellows Assemblies limit movement to
angulations in one plane. Hinged Assemblies are
normally used in sets of two or three to absorb
large amounts of expansion in high pressure piping
systems.

 Gimbaled Bellows Assemblies are designed to

absorb system pressure thrust while allowing
angulations in any plane. Gimbaled Assemblies,
when used in pairs or with a Single Hinged unit,
have the advantage of absorbing movements in
multi-planer piping systems.
 Types of Expansion Joints

• Restrained Type – Pressure Balanced Assemblies

   Pressure Balanced Elbow Assemblies are
used in applications where space limitations
preclude the use of main anchors. Pressure
thrust acting on the line bellows (bellows in the
media flow) is equalized by the balancing
bellows through a system of tie rods or linkages.
The only forces transmitted to equipment are
low spring forces created by the axial, lateral, or
angular movements. An elbow must be present
in the piping network to install this style of
expansion joint.

• Generally used at turbine inlet nozzle

System Preparation

• Spring Force
 The force requires to deflect an expansion joint
a specific amount.

 Based on the operating conditions, materials and

manufacturing methods used.

 Spring force must be restrained in order for the

joint to operate properly.

Spring force

Spring force imparts a resisting force

throughout the system like a spring would
when compressed or otherwise deflected.
System Preparation

• Pressure Thrust
M M

Force created by pressure

acting on a bellows.
Force is the system pressure
F F

times the effective area of the

bellows PRESSURE THRUST CONTAINED PRESSURE THRUST NO LONGER
MA
SYSTEM NOW REQUIRES
MA

BY PIPE. CONTAINED BY PIPE. MAIN ANCHORS.

Pressure thrust must be
contained with either main
anchors or restrained expansion The magnitude of pressure thrust force (Fs) in
joints designed to carry lbs. Is determined by the following equation:
pressure thrust loads
Fs= P a
Where: (P) is the pressure (psig)
And: (a) is the effective area of the
expansion joint
 Installation Guidelines

• Use of Anchors
   Main anchors are the most important to consider
from a design standpoint. They must resist the effects of
all forces acting upon them including pressure
thrust.These are pressure thrust, INTERMEDIATE
ANCHORS bellows spring resistance, frictional resistance
of pipe guides,and inertial forces at bends and elbows.

Main Anchor
Installation Guidelines

• Use of Anchors
    Intermediate anchors are used to divide a long
pipe run into shorter individual expanding sections, and
should be structurally capable of withstanding bellows
spring resistance and frictional forces only. Pressure PIPE
ALIGNMENT GUIDE thrust forces at this juncture are
completely balanced and have no influence on the design
of the anchor.
Intermediate
 Directional Anchors permit movement in one Anchor
direction only. The movement is often parallel to the
direction the lateral movement in installations where
combinations of axial and lateral movements are
encountered.
Installation Guidelines
• Pipe Guides & Supports
Must withstand all of the non-pressure
forces acting upon it by each of the pipe
sections to which it is attached. Are not
intended to withstand pressure thrust
force.

 Pipe Guides & Supports correct

alignment of the pipe adjoining an
expansion and prevents buckling of the
line.
Pipe Guides and Stability
 Buckling is caused by a combination of
the expansion joint flexibility and the
internal pressure loading on the pipe.
Installation Guidelines

• Pipe Supports U Bolt

   Pipe Supports is any device which permits free

movement of the piping while carrying the dead weight of
the pipe and any valves or attachments.

 Must be capable of carrying live weight

 Cannot be substituted for pipe alignment or planer

guides Spring
Hanger
 Pipe rings, U-bolts, roller supports, spring hangers
Application Engineering

• Restrained Type: Tied Assemblies Figure 1 EQUIPMENT

    Figure 1 Tied Single Assemblies are

often used to protect rotation equipment
from the effects of thermal expansion. The
tie rod restraint is designed to absorb
pressure thrust. TIED SINGLE
ASSEMBLY

IA
G
 Figure 2 A Tied Universal Assembly may PG
be required when movement in the piping
system is too great for a single tied
assembly. Figure 2

PG
IA

TIED UNIVERSAL
ASSEMBLY

It is good practice to
IA
keep the maximum
PG distance possible
between bellows.
Application Engineering

• Restrained Type: Hinged Bellows Assemblies

    Figure 1 Hinged Bellows Assemblies,
when used is sets of 2, are installed in a “Z”
offset, as shown, they can absorb large Figure 1
amounts of thermal movement in a piping PG
system. The thermal expansion in the offset IA
leg is absorbed by the natural flexibility of
the horizontal pipe runs. Pressure thrust is
contained by the hinge restraint, allowing HINGED BELLOWS
L2

intermediate anchors to be used. ASSEMBLY

HINGED BELLOWS L1
ASSEMBLY

It is good practice
to make (L1) the
L2
maximum possible
and (L2) a
IA minimum.
PG
Application Engineering
• Restrained Type: Hinged Bellows Assemblies
IA
    Figure 2 Hinged Bellows Assembly G
L1
systems can be designed to absorb thermal PG
Figure 2
movement in both the horizontal leg and
vertical offset leg. Location of the expansion HINGED
BELLOWS
joint should be as follows: Make the (L1) and ASSEMBLY
(L2) the maximum possible, (L3) the
L3
minimum possible. The hinge restraints is HINGED
BELLOWS
designed to absorb the pressure thrust and ASSEMBLY
weight of the pipe between the two hinge HINGED
L2
units. Forces on anchors and equipment BELLOWS
ASSEMBLY
connections are reduced to friction and low
offset forces.
L3

G
IA
Application Engineering

• Restrained Type: Hinged & Gimbal L2

IA
Bellows Assemblies HINGED
BELLOWS
ASSEMBLY
    Gimbal Bellows Assembly and Single PG
Hinged Bellows Assembly combination can
be used where the horizontal pipe leg in L3
insufficiently flexible to absorb thermal growth GIMBAL
BELLOWS
in the offset leg. It is good practice to make (L1) ASSEMBLY
and (L2) the maximum possible and (L3) a
minimum. A regular pipe guide must be used on L1
the lower pipe leg while a planer pipe guide is GIMBAL
used on the upper leg. BELLOWS
ASSEMBLY
G
L3
IA
Application Engineering

• Restrained Type: Pressure Balanced Assemblies

    Figure 1 This example shows a Single

Pressure Balanced Assembly used to IA
protect rotating equipment from the effect of Figure 1
thermal expansion between two intermediate
anchors (IA). In operation, the thermal
growth in the system compresses the line PRESSURE BALANCED
bellows (A). Internal pressure acting through ELBOW ASSEMBLY

the tie rods instantaneously elongates the EQUIPMENT

balancing bellows (B) an equal amount
B
providing a completely balanced systems.
A

If no lateral movement is
present, the number of
convolutions in bellows (A)
and (B) are equal.
Application Engineering

• Restrained Type: Pressure Balanced Assemblies

PRESSURE BALANCED
B
    Figure 2 A Single Pressure Balanced ELBOW ASSEMBLY
A Figure 2
Assembly can be used to absorb lateral and G
axial movement. In figure 2, bellows (A) has
IA
sufficient convolutions to absorb both axial
and lateral movement present in the piping
system. The balancing bellows (B) requires G
only sufficient convolutions to compensate for
the axial movement present in the horizontal
line. Intermediate anchors (IA) and pipe
alignment guides (G) should be installed in
the locations shown.

EQUIPMENT
Application Engineering

• Restrained Type: Pressure Balanced Assemblies

    Figure 3 Universal Pressure Balanced
Assembly- There are many installations where the PRESSURE BALANCED
B ELBOW ASSEMBLY Figure 3
lateral movement present in the system exceeds A2
the capability of a single pressure balanced bellows A1
G
assembly. This problem is best overcome by the IA
use of a Universal Pressure Balanced Assembly as
shown. The line bellows (A1) and (A2) are linked G
by a section of pipe that allows greater lateral
movement in addition to the axial movement
present. The balancing bellows (B) is designed to
compensate for axial movement only. Tie rods link
both sets of bellows and absorb pressure thrust,
resulting in low forces on adjacent equipment and
structures. EQUIPMENT
Sample drawing of bellow
7. Buried piping analysis

o CAESAR II Underground Pipe Modeler

 Allows the direct input of soil properties.
 Breaks down straight and curved lengths of
pipe to locate soil restraints
 Allows the direct input of user-defined soil
stiffness on a per length of pipe basis.
 allows users to define which part of the
piping system is buried.
 allows users to define mesh spacing at
specific element ends.
 allows the input of user-defined soil stiffness
 Using the Underground Pipe Modeler

 When the Buried Pipe Modeler is initially started up, the

following screen appears:
o Buried pipe deforms laterally in areas immediately adjacent
to changes indirections (i.e. bends and tees).
o In areas far removed from bends and tees the
deformation is primarily axial. Where the deformation is
“lateral", smaller elements are needed to properly distribute
the forces from the pipe to the soil.
o The length over which the pipe deflects laterally is termed the
“lateral bearing length” and can be calculated by the
equation:

Lb = 0.75() [4EI/Ktr]0.25
Where:
E = Pipe modulus of elasticity
I = Pipe moment of inertia
K tr = Transverse soil stiffness on a per length basis,
 Zone Definitions

 Zone- 1= Lb (min. three elements)

 Zone- 2= Intermediate Length min. four
elements Starting from 1.5Lb
progressing in equal increment
= 50 X Do (Max.)
o Zone- 3= Axial Displacement length
= 100 X Do (Max.)
 Soil Model No.
A nonzero entry in this column implies that the
associated element is buried.
A ‘1’ in this column implies that the user wishes to
enter user defined stiffness,
‘2’ in this column implies Caesar defined stiffness
o Max. 15 different soil models may be
entered for a single job
 All densities on buried pipe elements are zeroed,
to simulate the continuous support of the pipe
weight.
 Soil support are modeled as bi-linear springs
having an initial stiffness=1, an ultimate load and
yield stiffness
Characteristics of Bi-linear Supports
 Soil type
 Soil type
 Min 1500 mm
 Soil type
 Max(Degree of
compaction backfill)
 1.5 % of buried length
• Axial Ultimate Load (Fax) :-
Fax = μD[ (2 ρs H) + (ρp t) + (ρf )(D/4) ]
Where:
μ = Friction coefficient, typical values are:
0.4 for silt
0.5 for sand
0.6 for gravel
0.6 for clay or Su/600
Su = Undrained shear strength
D = Pipe diameter
ρs = Soil density
H = Buried depth to the top of pipe
ρp = Pipe density
t = Pipe nominal wall thickness
ρf = Fluid density

• Yield Displacement (yd):

yd= Yield Displacement Factor × (H+D)

Note: The Yield Displacement Factor defaults to 0.015.

• Axial Stiffness (Kax) on a per length of pipe basis:

Kax=Fax / yd

• Transverse Stiffness (Ktr) on a per length of pipe basis:

Ktr= Ftr / yd
 Transverse Ultimate
Load(Ftr):-

Where:
 = Angle of internal
friction, typical values are:
 27-45 for sand
 26-35 for silt
 0 for clay
 OCM = Overburden
Compaction Multiplier
8.Outgoing data from stress dept. to layout and
other dept.

To layout team:-
 Critical line list
 Stress isometrics with mark-up of support
legend node no., gap etc.
 Spring/Rigid rod Hanger spacing feasibility
check.
 Any other special supporting arguments/
combination
 Location of Expansion Loop & Anchor Bay over
pipe rack
 Location of expansion joint with adequate
supporting
 Mark higher Axial disp.>150mm & lateral
disp.>50mm over stress isometric.
Civil Info:-

 Pipe support loading (Anchor bay, pipe rack)

 Slot arrangement on civil structure in case of

Reboiler & Silencer piping design

 Mark proper Fx, Fy, Fz & Mx, My, Mz

coordinates w.r.t. north direction
Mechanical Info:-
 Vessel cleat loading
 Fixed/Sliding sides in case of heat exchangers.
Fixed side always to be on tube bundle removal
side until & unless any specific analysis
requirements like qualify a higher size nozzle or
larger differential expansion to be absorbed
 Request for WRC 107/297 or in extreme case
Finite element analysis for severe nozzle load
conditions
 Lug slot arrangement (if any) in case of
Reboiler/Silencer.
 Actual nozzle loading format exceeding
allowable
 Circumferential, longitudinal and axial forces
and moments for standard axis
 Local forces & moment in case of skewed
nozzle
 Shear, axial force & Bending, torsional
moment in case of nozzle at dish-end