Flexibility Analysis for High

Temperature Piping System -

Case Study for Combined Cycle
Power Plant.
What is Pipe ?
 It is a Tubular item made of metal, plastic, glass etc. meant for
conveying Liquid, Gas or any thing that flows.
 It is a very important component for any industrial plant. And it’s
engineering plays a major part in overall engineering of a Plant

High Temperature Piping

❜ In Power plant there are some piping which carries steam at high
pressure and temperature.. These pipes carries the main cycle
steam and water of the steam power plant.
❜ Pipe material selection - to withstand the high pressure and high
temperature.
❜ Steam pipes run at very high temperature and the hot pipes
expand.There should be enough flexibility in these pipes so that
pipe can itself withstand this thermal loading and high loads
should not transferred to the nozzles of Turbine or Pumps.
Pipe Stress Analysis
❜ The process of checking the stress developed in the piping due to
various loading is called Pipe Stress Analysis/Flexibility analysis.
❜ It is a discipline highly interrelated with piping layout and pipe
support design and normally associated with analysis of stresses in a
piping system, primarily due to thermal expansion or contraction.
❜ The objective of the Pipe flexibility analysis is to ensure safety against
failure of the piping material or anchor points from overstress.
❜ Check pipe stresses with governing codes (as Design Base
Document) .
❜ Support load & movement for various loading conditions.
❜ Check the terminal point loading (Forces & Moments) generated from
pipe to the connected equipment.
Types of Loads
 Sustained Loads Also loads on piping can
– Dead Weight (Weight Of be classified as
Pipe, Fittings, Fluid in Pipe,
Piping Components valves,
 Static Loads
valve Operators, flanges so – Dead Weight
on.) – Thermal Expansion and
contraction effect
 Thermal Expansion Loads
– Effects of Support, anchor
– Due to the Temperature
and thermal movements
 Occasional Loads – Internal and external loadings
– Seismic  Dynamic Loads
– Wind
– Impact forces
– Snow and etc.,
– Wind Load
– Seismic Load
– Steam & Water Hammer
effects
– Discharge Loads
Stresses in Piping
 Hoop’s Stress
 Longitudinal Stress
 Axial Stress
 Radial Stress
 Bending Stress
 Torsion
The failure of structural part occurs when a certain function of
the stress or strain components reaches a critical value. The
peculiarity of the piping system is such that, there are
possibilities of every possible stresses being generated in it
Stresses in Piping…..Contd.
 Circumferential stresses - Due to internal pressure
 Bending and torsional stresses - Due to dead load, snow and
ice, wind or earthquake.
 Primary stresses - Due to external effects are the direct
longitudinal
 Due to pressure inside the pipe - Three-dimensional stresses
in longitudinal, circumferential and radial direction are
generated.
 Bending and torsional stress - Due to thermal expansion or
contraction because of temperature variations, bending and
torsional stress are generated.
 There are the direct, bending and torsional stresses - Due to
the restrained thermal loadings (the restrained thermal analysis, the
external forces being supplied in this case by the line of anchors and other
restraints.)
Methods of Flexibility Analysis
 Code Method
 Approximate Methods
– Guided Cantilever Method
– Chart Solutions
– Mitchell Bridge Method
 Exact Analytical Methods
– Simplified Kellogg's Method
– General Kellogg's Method
– Using Finite Element Technique
 Model Tests
Finite Element Method
 It is a numerical method of solution of complex problems, which
is based on the general principle of "going from part to whole".
Finite element method converts a continuous system into a
discrete system. (Linear, three dimensional finite analysis
program)

Derivation of finite element equations

[K] * {u} = {F}
where,
[K] = global stiffness matrix,
{U} = global displacement vector,
{F} = global load vector
Pipe Flexibility Analysis
 Inputs and Various Steps
in Flexibility Analysis
– Geometric layout of Pipe
– Pipe supporting configuration
– Pipe Diameter and Thickness
– Pressure inside Pipe
– Cold and Hot temperatures of
Pipe
– Weight of Pipe and insulation
– Weight of carrying Fluid
– Pipe material Property (Young’s
Modulus, Thermal Expansion
Coefficient)
– Thrust on pipe due to
blowing wind.
– Thrust on pipe due to
earthquake
– Load of Snow on pipe
– Any transient loading like
Steam Hammer load
– Any other load on the
piping
Pipe Flexibility Analysis…Contd.
 Piping Analysis Software
– PIPSYS is a PC-based computer program. This software package
is an engineering tool used in the mechanical design and analysis
of piping systems.
– There are many other commercial software available are SAP-IV,
COSMOS/M, NISA, CAESAR-II & CAE PIPE.
 Outputs
– Stress of the pipe at various loading conditions
– Load at various supports and restrains.
– Movement of pipe at support locations
– Pipe terminal point (anchor, equipment ) loading.
Piping Flexibility
 The major requirements in high temperature piping design is to
provide adequate flexibility for in the piping system to allow the
thermal expansion of the pipe without causing excessive stresses
and without exceeding the terminal equipment allowable loadings.

 Flexibility can be provided using Expansion loops, offsets, bends,

etc., In piping designing, elbows, Bends, and Pipe Expansion
Loops normally provide adequate flexibility for thermal expansion.
– The stress can be reduced by introducing an expansion loop.
– Expansion loops provided in the pipe length perpendicular to
the direction of straight pipe.
– The expansion of straight pipe will be accommodated between
the anchors by flexing the loop legs, thus reducing the stress
in the pipe and loading on anchor.
Expansion Loops
Consideration for Piping Flexibility
 Avoid the use of a straight pipe run of pipe between two-equipment
connection or between two anchor points.
 A piping system between two anchor points in a single plane shall have as
a minimum configuration L-Shaped consisting of two runs of pipe and a
single elbow.
 A piping system between two anchor points with the piping in two planes
may consist of Two L-Shaped runs of pipe. For e.g. One L-shaped run in
the horizontal plane and another in vertical plane.
 A three-plane configuration may consist of a series of L-shaped runs or U-
shaped expansion loops designed into the normal routing of the system.
 For high temperature piping following minimum consideration are required
to ensure adequate flexibility :
– Adequate developed length of piping system between anchors/
equipment connection with in the physical design constraints as
functional design requirements.
Consideration for Piping Flexibility….
Contd..
– Provision of flexible supports, when up or down movement of pipe at
support location will be made possible
– Provide single or multi direction restrain at strategic location to guide
the pipe thermal expansion in a predictable manner and also to
constraint where necessary.
– Further guides and restrain help to the control the excessive pipe
rotation and resulting the stress in the pipe on moments on the
equipment nozzle.
– Provide flexible supports in vertical raiser.

 For systems consisting of large diameter main and numerous smaller

branch lines, the designer must ascertain that the branches are flexible
enough to with stand the expansion in the main header.
 Systems that are purged by steam or hot gas must be reviewed to assure
that they will be flexible during the purging operation.
 Closed relief valve and hot blow down systems should be given special
attentions.
Flexibility of Piping - Example
Flexibility of Piping - Example
Flexibility of Piping - Example
Expansion Loop
 Types of Pipe Supports Constant Load Spring

There are three general types

❜ Rigid type (no flexibility in the
direction of restrain)
Variable Spring
❜ Spring type (Allows pipe movement
in direction of loading)
❜ Dynamic Support (Degree of
restrain depends on acceleration of
load)
Rigid Hanger

Rigid Support
There are two types of spring support
❜ Variable load type, here support
load changes as the pipe moves.
❜ Constant load support, the load Dynamic Support,
remains constant within some range Snubber
of movement.
Rigid Support
 Case Study for Combined Cycle
Power Plant
Main Steam Piping System
 The High Pressure (HP) steam system is designed per
ASME-B31.1(Power Piping Code) to convey HP
superheated steam, from the HP superheater outlet to
the high pressure section of the steam turbine. HP
steam line is provided with a bypass line, with a
combined pressure reducing and steam
desuperheating valve and is connected to the
Condenser.
 Normal Operation
 Start-Up/Shutdown Operation
 Piping Material Selection
 Piping material selection is based on established industry practices for the
temperature, pressures, services and fluid type

 General water and steam services less than 750 F ASTM A 106 Grade B or A53 Gr. B
 Steam Piping above 750 F less than 955 F ASTM A 335 Grade P11
 Steam piping above 955 F to 1050 F ASTM A 335 Grade P 22
 Steam piping above 1051 F to 1200 F ASTM A 335 Grade P 91
 Flashing heater drain service ASTM A 335 Grade P5
 Mild corrosive service ASTM A 312 or A 367, Grade TP304
 Severe corrosive service ASTM A 312 or A 367, Grade TP316
 Low pressure and temperature ASTM A-53 Grade B
 Concentrated acid handling systems Alloy 20 or HDPE / PVC / Rubber lined
 Fire protection Carbon steel
 Design data
 Pipe Size = 8 inches for Main Steam Pipe
 Pipe Thickness = 160 Sch
 Insulation Thickness = 7.5 inches
 Pipe size = 24 inches for Bypass connection
 Pipe Thickness = STD
 Insulation Thickness = 2.5 inches
 Design Temperature = 955.4 ° F
 Design Pressure = 1450 psi
 Pipe Material = ASTM A335 P22
 Insulation Material = Calcium silicate per ASTM C533 for heat retention
 Pipe Construction = Seamless
 Flange type = Not Allowed
Fittings Greater than 2 inch
 ASTM Spec. = A234 WP22
 ASME STD. Type = B16.9, B16.28
 Type = Butt Weld
Fittings Less than 2 inch
 ASTM Spec. = A182 F22
 ASME STD. Type = B16.11
 Rating = 9000 Class
 Type = Socket Weld
 Attemperator weight = 1322.5 lbs per 7.87ft
Stress/Node Isometric
Analysis Methodology
 The Piping System is considered as an assembly of many pipe segments connected by
analytical node points.
 The stress is computed based on internal forces and moments in each segment at all node

points.
 The reactions at each pipe support location are calculated; force equilibrium check is made
at all node on support points.
 The stress value as calculated in the analysis for sustained load and thermal expansion
load at each node will be verified as per ASME B31.1 code equations for code compliance.

Dead weight Analysis

 The PIPSYS checks the node formation and end connection of fittings, if it is properly
sequenced it will further proceed by forming a matrix for further analysis else error will be
indicated for the specified Node and the same should be corrected.
 it is checking the dead weight supporting is within the permissible limit. If the pipe is not
properly supported in dead weight the support location should be changed to minimize the
sag.
NODE TYPE FACTOR STRESS IN PSI DISPLACEMENTS IN INCHES (GLOBAL
COORDINATE)
I (I*M)/Z X Y Z
--------------------------------------------------------------------
5 7 1.46 1389. 0.000 0.000 0.000
Pipe Behaviour In Thermal Condition - Iteration -I

Nodes Failing

Nodes Failing
Maximum stressed Node - Iteration I
NODE NODE STRESS ALLOWABLE RATIO
TYPE (PSI) STRESS(PSI)
95 8 144000. 29180. 4.935
320 1 60800. 29028. 2.095
50 1 42200. 28083. 1.503
5 7 33000. 28619. 1.153
55 8 31400. 28639. 1.096
 Ratio are more than 1, means that the stresses are exceeding the allowable stress limits and thus the nodes get
fails.

Equipment Nozzle reaction

Hrsg
LOAD CASE FORCES (LBS) MOMENTS (FT-LBS)
HOT & WEIGHT FR = 4082. MR = 60244.
COLD & WEIGHT FR = 3516. MR = 72069
Turbine.
HOT & WEIGHT FR = 6068. MR = 36673.
COLD & WEIGHT FR = 6679. MR = 44044.
Condenser
HOT & WEIGHT FR = 1102. MR = 6646.
COLD & WEIGHT FR = 1734. MR = 9026.
 Pipe Behaviour In Thermal Condition - Iteration -II

Expansion Loops

Guide Support

Spring Hanger
Maximum stressed Node - Iteration II
NODE NODE STRESS ALLOWABLE RATIO
TYPE (PSI) STRESS(PSI)
325 11 24500. 29443. 0.832
305 8 21700. 29332. 0.740
5 7 19800. 28606. 0.692
330 7 18600. 29494. 0.631
55 8 16000. 28651. 0.558
95 8 14400. 29015. 0.496
Equipment Nozzle reaction
Hrsg
LOAD CASE FORCES (LBS) MOMENTS (FT-LBS)
HOT & WEIGHT FR = 3924. MR = 56488.
COLD & WEIGHT FR = 3260. MR = 67373
Turbine.
HOT & WEIGHT FR = 5983. MR = 33526.
COLD & WEIGHT FR = 6503. MR = 40128
Condenser
HOT & WEIGHT FR = 1109. MR = 9508.
COLD & WEIGHT FR = 1674. MR = 12032.
Final Iteration
 As the same Lot of trail and error iteration has been done to keep the pipe within
permissible limit in dead weight, minimum stresses at all nodes and all the three
equipment nozzles within the allowable limits as specified by the manufacturer of the
same.

 Finally by doing lot of iteration the best solution has arrived which gives

 Minimum stresses in Piping

 Meets the code limits and
 Meets the Equipment forces and moments.
Conclusion
As seen in the case study in detail, the piping stress analysis checks with

 The Acceptance of piping system per applicable design code,

 Requirement related to equipment limitation and
which ensures

 The Safety of piping and piping components against failure

 Maintain system operability
 to comply with legislation / Indian boiler regulation
 the piping is well supported and does not sag or deflect in an unsightly way
under its own weight
 the deflections are well controlled when thermal and other loads are
applied
 the loads and moments imposed on machinery and vessels by the thermal
growth of the attached piping are not excessive
Gives the input for

 Input to civil for Structure design

 And loads and displacement for support design and for hanger design.
Thank You