PIPE STRESS ANALYSIS WORK

By: Tengku Syahdilan

Senior Piping Mechanical Engineer
PT KBR Engineers Indonesia
AGENDA

1. Why Do We Perform Pipe Stress Analysis?.

2. Pipe Stress Engineer Scope of Work.
3. Theory of Pipe Stress Analysis.
4. Pipe Supports.
5. Applicable Codes.
6. Pipe Stress Analysis using Caesar II 5.20.
7. Code Compliances and Nozzle Evaluation.
8. Designer Responsibilities Related to Stress Engineering
Work.
1. Why Do We Perform Pipe Stress Analysis?

• To keep stresses in the pipe and

fittings within code allowable.
• To keep nozzle loadings on attached
equipment within allowable of
manufacturers or recognized
standards (API 661, API 650 etc)
• To calculate design loads for sizing
supports and restraints.
• To determine piping displacements
for interference checks.
• To solve dynamic problems in
piping, i.e.: mechanical and acoustic
vibration, fluid hammer, pulsation,
transient flow and relief valve
discharge.
• To optimize piping design.
• To prevent flange leakage joint.
2. Pipe Stress Engineer Scope of Work

Develop Critical Review Stress No Revise the Piping

Acceptable?
Lines List Isometric Layout & Isometric

- Category 3 (Computer Analysis). - Modify pipe support

-Depend on Client
- Category 4 (Approximate Method). type and location.
Specification.
Yes - Add elbow to
- Category 5 (Visual Exam.).
increase
piping flexibility.

Review and
Review 3D Review and
Comment on
Model and Approve the
Conceptual
Support Scheme Stress Isometric
Studies
-Stresses are within allowable. -To prepare pipe support selection.
-Nozzle loads are within allowable. -To select pipe support based on
-Anchor and guide support location are pipe support selection criteria.
already fixed and already informed the -To check the 3D Model is comply
loading values to Civil Department. with the latest stress calculation or
not.
Pipe Stress Analysis Category

Method of Analysis:
1. Category 3
Using computer program
such as: Caesar II (Coade),
Autopipe (Bentley), PIPANL-
3 (SSD) etc.

2. Category 4
Using approximate methods
such as: the Kellogg,
Grinnell or Tube Turn
methods.

3. Category 5
Visual inspection with or
without the aid of guided
cantilever chart or similar
short cut methods.

Ref: KBR Design Manual

Subject No: 4100
3. Theory of Pipe Stress Analysis
3. 1. Stress-Strain Curve

σ ε x E

Where:
σ = Stress (kg/cm2)
ε = Strain
E = Young’s Modulus (kg/cm2)
Allowable stress is the yield strength
divided by safety factor.
I.E : Carbon Steel Pipe below creep
range commonly has allowable stress
is 2/3* σy or ¼* σu. For detail see
Table A-1 in B31.3
3. 2. Basic Stress Concepts

Stress due to axial force F F

σ = F/A
F = Axial force acting on cross section (kg)
A = Cross-sectional of pipe (mm2)

Stress due to bending and torsion

σb = Mb / Z
σt = Mt / 2Z Mt
Mb = Bending moment (kg-mm)
Mt = Torsional moment (kg-mm) Mb
Z = Section modulus of pipe (mm3)

Stress due to internal pressure

σH = PDi / 2t (Hoop)
σL = PDi / 4t (Longitudinal)
P = Design pressure (kg/mm2)
Di = Inner diameter (mm) σL
t = Thickness of pipe (mm)
σH P
3. 3. Thermal Effect

Thermal Expansion
δ = ΔT x α x L ; (mm)
Carbon Steel +/- 1 mm/m for 100oC
Stainless Steel +/- 1.35 mm/m for 100oC
δ (Pushed)
Thermal Stress
σ = ε x Ε = δ/L x E
= ΔT x α x E

Reaction Force Damage

F=σxA Force

Example: 1meter length of 8” NPS CS Pipe STD at 100 oC.

T ambient = 20oC
1. δ = (100-20)x12x10-6x1000 = 0.96 mm
2. σ = (100-20)x12x10-6x20000 = 19.2 kg/mm2
3. F = 19.2 x π x (2192-2032)/4 = 27.6 ton
4. Pipe Support

Control Valve
Sliding Support
Tight Support Adjustable Guide
Variable Spring Support

4.1. Support Around Control Valve 4.2. Spring and Adjustable Support
 Pad
Shoe

Sliding Plate
4.3. Hold Down Guide

Structure 4.4. Anchor

Eye Bolt

Spring Hanger

Turnbuckle

Pipe Clamp

4.6. Stopper
4.5. Spring Hanger Assembly
5. Applicable Codes
• 5.1. Piping Design Code
 ASME B31.1 Power Piping
 ASME B31.3 Process Piping
 ASME B31.4 Pipeline (Hydrocarbon)
 ASME B31.8 Pipeline (Gas)
 ASME Section III Nuclear Component
Design
ASME: The American Society of Mechanical Engineers 
API: American Petroleum Institute  ASME SEC VIII Pressure Vessel
NEMA: National Electrical Manufacturers Association
WRC: Welding Research Council
• 5.2. Related Code for Nozzle
Evaluation
 API Std 610 Centrifugal Pump
 API Std 611 Steam Turbines
 API Std 617 Centrifugal Compressor
 API Std 618 Reciprocating Compressor
 API Std 650 Welded Steel Tanks
 API Std 560 Fired Heaters (Furnace)
 API STD 661 Air-Cooled Heat Exchangers
(AFC)
NEMA SM23 Steam Turbines
 WRC 107, WRC 297 Local Stress on
Nozzles
 6. Pipe Stress Analysis using Caesar II 4.50
6.1. Required Data:
• Piping Configuration complete with
Spring Support dimension.
• Material Spec. :Size, Thickness,
Vertical Guide Material Properties, method of
bracing, etc.
• LDT (Line Designation Table):
Pressure, Temperature, Insulation
Thickness, Density etc.
Spring Hanger (Typ. 12ea) • Equipment Drawing to determine
V-1002 nozzle movement.

Trunnion (Typ. 3ea)

• Wind and earthquake loading.
• Standard valve and flange weight.
• Number of operating cycles if any.
V-1001 • Misc. item drawing such as
Guide (Typ. 3ea) silencer etc.
6.2. Item need to be concerned:
K-3301C
• Boundary Condition.
K-3301B • Operating Case, i.e: pump, run or
stand-by.
K-3301A • Friction.
7. Code Compliances and Nozzle Evaluation
7.1 Primary vs. Secondary Loads
Primary Load Characteristics:
1. Primary loads are usually force
driven (gravity, pressure, spring
force, relief valve, fluid hammer etc).
2. Primary loads are not self-limiting.
3. Primary Loads are typically not
cyclic in nature.
4. Allowable limits for primary stress
are related to the material yield
stress, the ultimate strength or
time-dependent stress rupture due
to sustained load.
5. Excessive load causes plastic
deformation and rupture.
Secondary Load Characteristics:
1. Secondary loads are usually
displacement driven (thermal exp, anchor
movement, settlement, vibration etc).
2. Secondary loads are almost self-limiting.
3. Secondary Loads are typically cyclic in
nature except settlement.
4. Allowable limits for secondary stress are
based upon cyclic and fatigue failure
modes.
5. A single application of load never
produce failure.
 7.2. Code Stress Equations

• 7.2.1. B31.1 Power Piping 7.2.2. B31.3 Process Piping

0.75iM A Pd o Fax [(ii M i ) 2  (io M o ) 2 ]1/ 2 Pd o
S sus    SH S sus     SH
Z 4t Am Z 4t
iM 2
[(i M ) 2  (io M o* ) 2  4M T ]1/ 2
S EXP  C  S A  f (1.25SC  1.25S H  S SUS ) S EXP  i i*  S A  f (1.25SC  1.25S H  S SUS )
Z Z

0.75iM A 0.75iM B Pd o SOCC  S SUS  S l  1.33S H

SOCC     kS H
Z Z 4t
Where:
MA = Resultant moment due to sustained, kg-mm
SH = Allowable stress at operating temperature, kg/mm 2
i = Intensification factor
Mc = Resultant moment due to expansion, kg-mm
SA = Allowable expansion stress, kg/mm 2
MB = Resultant moment due to occasional, kg-mm
k = occasional factor
= 1.2 for loads occurring less than 1% of the time
= 1.15 for loads occurring less than 10% of the time
SC = Allowable stress at installation temperature, kg/mm2
Where:
Fax= Axial force due to sustained, kg
Mi = In-plane bending moment due to sustained, kg-mm
Mo = Out-plane bending moment due to sustained, kg-mm
Mi* = Range of in-plane bending moment due to expansion, kg-mm
Mo* = Range of out-plane bending moment due to expansion, kg-mm
SH = Allowable stress at operating temperature, kg/mm 2
ii ,io = In-plane, out-plane intensification factor
MT = Torsional moment due to expansion, kg-mm
SA = Allowable expansion stress, kg/mm2
SC = Allowable stress at installation temperature, kg/mm 2
Sl = Bending stress due to occasional loads such as wind/earthquake
f = Stress range reduction factor
7.2.3. B31.4 Liquid Transportation Piping 7.2.4. B31.8 Gas Transportation Piping

S sus  Slp  Sb  0.75 x 0.72 x SYield S sus  S lp  S b  0.75 S x F x T

2 2
2 2
S EXP  ( Sb*  4St )1/ 2  0.72SYield S EXP  ( Sb*  4St )1/ 2  0.72S
S OPE  F EaT  v S H  S EXP  S SUS (1  F )  0.9SYield SOPE  S EXP  S SUS  S

SOCC  Slp  Sb**  0.75 x 0.72 x k x SYield S OCC  S lp  S b**  0.75 x S x F x T x k

Where:
Where:
Slp = Longitudinal pressure stress, kg/mm 2
Slp = Longitudinal pressure stress, kg/mm 2
Sb = Bending stress due to sustained, kg/mm 2
Sb = Bending stress due to sustained, kg/mm 2
Sb* = Range of bending stress due to expansion, kg/mm 2
Sb* = Range of bending stress due to expansion, kg/mm 2
St = Range of torsional stress due to expansion, kg/mm 2
St = Range of torsional stress due to expansion, kg/mm 2
Sb** = Bending stress due occasional, kg/mm2
Sb** = Bending stress due occasional, kg/mm 2
Syield = Specified minimum yield stress material, kg/mm 2
S = Specified minimum yield stress material, kg/mm 2
F = 1 (under ground pipeline); 0 (above ground pipeline)
F = Construction type
E = Modulus of Elasticity
T = Temperature derating factor
a = Thermal expansion coefficient
k = Occasional load factor
ΔT = Temperature change of pipe from ambient
v = Poisson’s ratio
SH = Hoop stress kg/mm2
k = Occasional load factor
7.3. Nozzle Evaluation

7.3.1. Pump (API Std 610)

7.3.2. AFC (API Std 661)
7.3.3. Pressure Vessel/Heat Exchanger (KBR Specification)

Note: For detail see Halliburton KBR

Specification Doc. No: 308-7080-ST-54-101
7.3.4. Furnace (API Std 560)
7.3.5. Compressor and Turbines (NEMA SM23)

3FR  M R  500 De

Individual Forces and Moments

Fx = 50 Dc Mx = 250 Dc
Fy = 125 Dc My = 125 Dc
Fz = 100 Dc Mz = 125 Dc

Total Resultant Forces and Moments

3FR  M R  500 De 3FR  M R  500 De

Combine Loads for Inlet and Outlet

2 FC  M C  250 DC
7.3.6. Tanks (API Std 650)

Note:
Appendix P on API Std 650 shown that the nomogram is
only applicable for tanks larger than 36 m in diameter.
If not we will use WRC297 to verify our piping loads are
within allowable or not , but it will be better to ask Tank
Department to verify our piping loads.
API Std 650 is not mention how to verify the nozzle loads at
roof of tank.
8. Designer Responsibilities Related to Stress Analysis Work

• To prepare stress sketch/isometric drawing based on critical line

list from stress engineer.
• To prepare piping loading information for Civil and Equipment
Department and Stress Engineer shall indicate the loads.
• To utilize the span table for horizontal support (guide) and
vertical support (resting).
• To select a proper pipe support based on pipe support selection
criteria and stress sketch from stress engineer.
• To inform the clearance for spring support installation.
• To prepare misc. support drawing as needed and then shall be
verified by Stress Engineer.
• Etc.
•
8.1. Piping Loading Information to Equipment

Plan View
8.2. Around Pump

Items to be concerned:
1. Shortest suction line shall be planned to
minimize pressure loss.
2. Adjustable supports shall be installed for
suction and discharge line for pump
maintenance and alignment and the
location as close as possible to the
nozzle.
3. Care shall be taken in thermal stress
calculations because the entire piping
does not always have the same
temperature, depend on operation plan.
4. To relieve reaction force and moment
due to thermal stress on the piping,
expansion loops and restraint supports
such as anchor, stopper, guide, resting
Adjustable Support and spring support shall be used.
8.3. Around Reactor and Fired Heater

Reactor

Constant Hanger

Lift Off

Sway Brace
Items to be concerned:
Constant Hanger
1. Piping shall be designed to have
sufficient flexibility but it shall be
arranged as short as possible.
2. Piping support around reactor shall be
selected to eliminate the vibration and
Sway Brace
excessive forces and moments to the
reactor nozzle due to thermal stress.
Fixed type support shall be installed as
close as possible from the nozzle.
3. Sway brace is vibration eliminator and
identical to variable hanger in their
resistance against thermal expansion, so
Adjustable Guide should be installed at location where the
thermal displacement is as smaller as
Fired Heater possible.
8.4. Around Compressor
Items to be concerned:
Re-strut
Re-strut 1. Piping route shall be flexible to prevent
Compressor excessive forces and moments on the
Compressor compressor nozzle.
2. Piping support shall be installed well
balanced so no excessive forces and
moments on the compressor nozzle.
Adjustable
Adjustable Guide
Guide
3. Piping connected to and from suction
and discharge of compressor shall be
equipped with vibration proof as
required.
4. Vibration proof piping support shall
allows piping movement caused by
thermal expansion and prevent piping
vibration caused by compressor.
5. Sleeper support shall be adopted to
abate the vibration of piping and shall
Vessel
be not connected or closed to
compressor shelter to prevent sleeper
piping vibration is transmitted to
shelter.
6. To check the natural frequency of
piping system against compressor.
7. Expansion joint shall not be used for
Re-strut vibrating line which may cause
damage.
8.5. Around AFC

Items to be concerned:
1. Support arrangement of piping
manifold shall be prepared to make it
simple and economic.
2. Piping route shall be flexible to prevent
excessive forces and moments on the
AFC nozzle.
3. Piping support around AFC shall be
selected to eliminate the vibration and
excessive forces and moments to the
AFC nozzle due to thermal stress.
Stopper type support shall be installed
as close as possible from the center of
AFC piping manifold.
4. Vibration due to slug force can be
eliminated by install properly stopper
Stopper and guide support.

Vessel
THE END