Piping Stress Analysis Training

Introduction and How to Analyze using CAE Software

By: Ferdian Harjono & Yono Hendriyana
2014/06/14
Timeline (2014/06/17) :
08:00 10:00 -> Basic Piping Introduction & Training
Overview
10:00 10:30 -> Coffee Break
10:30 12:00 -> Introduction to Pipe Stress Analysis &
Code Compliance
12:00 13:30 -> Lunch Break
13:30 15:30 -> Basic Piping Stress Analysis Theory
Timeline (2014/06/18) :
08:00 10:00 -> Piping Stress Analysis Workflow
10:00 10:30 -> Coffee Break
10:30 12:00 -> Piping Stress Analysis Workflow
(Contd)
12:00 13:30 -> Lunch Break
13:30 15:30 -> Equipment Analysis
Timeline (2014/06/19) :
08:00 10:00 -> Introduction & Software Installation
10:00 10:30 -> Coffee Break
10:30 12:00 -> Basic Modelling Technique Using
CAE Software (CAESAR II)
12:00 13:30 -> Lunch Break
13:30 15:30 -> Complete System Modelling
Timeline (2014/06/20) :
08:00 10:00 -> Equipment and Nozzle Modelling
10:00 10:30 -> Coffee Break
10:30 12:00 -> Static Analysis
12:00 13:30 -> Lunch Break
13:30 15:30 -> Static Result & Flange Leakage
Check
Overview :
Piping System: Definition
Scope of Work of Piping System Subfield
Basic Pipe Stress Analysis : Why & How?
Objectives of Pipe Stress Analysis
Codes & Standards
Terminology of Stress
Loads & Stresses in Piping

Overview :
Piping Flexibility
Piping Support: Purpose
Pipe Support Span Calculation
Pipe Support Type
Piping Stress Engineer Workflow

Piping System: Definition
A System of pipes, used to Transport fluids from one place to
another, including pipe fittings, valves, safety devices, etc.

Subfield of Piping System:
1. Piping Material
2. Piping Design
3. Piping Stress Analysis
Scope of Work of Piping System
Subfield
1. Piping Material
- Material Selection, Specification for welding, insulation,
painting, fabrication, etc.
2. Piping Design
- Designing Piping System from one equipment to another
equipment / one area to another area based on several
design basis
3. Piping Stress Analysis
- Analyzing the stresses in piping system to assure the safety
of the plant (enough flexibility = No overstress occur in
the piping system)
Basic Pipe Stress Analysis: Why &
How?
Pipe Stress Analysis
Why? Safety
Piping Stress Analysis adalah suatu metode terpenting untuk
meyakinkan dan menetapkan secara numerik bahwa sistem pemipaan
dan engineering adalah aman Achmad Chamsudi
Actual Loads not exceed Allowable Loads Codes&Standards

How?
Analyze the piping system using piping stress analysis software (CAESAR II
/ AutoPIPE)
Limit the Stresses in piping
Limit the deflection in piping
Limit the loads on connected equipment
Limit the loads on supports
Check leakage at flange joints
Avoid unintentional disengagement of pipes from support
Avoid excessive displacement
Objectives of Pipe Stress Analysis
Limit the Stress in Piping
Limit the Deflection in Piping

Limit the Loads on Connected Equipment
Limit the Loads on Support
2000
0
Check Leakage at Flange Joints
Check Leakage at Flange Joints (Contd)
Check Leakage at Flange Joints (Contd)
Avoid Unintentional Disengagement of
Pipes from Support
Avoid Excessive Displacement
Codes & Standards
Codes : General rules for design, materials, fabrication,
installation, and inspection prepared in such manner that
it can be adopted and made into law
Standards : Documents prepared with the basis of proper
engineering practice and written with mandatory
requirement
+ Beneficial : + Consistency and safety in design
+ Avoiding chances of failure
+ Reduction in plant shutdown
Mandatory Requirement from Codes
Piping component Thickness calculation for internal pressure
Piping component Thickness calculation for external pressure
Reinforcement requirement for branch
Minimum flexibility requirement
Piping support and their design
Allowable stresses for various materials
Piping Fabrication and layout requirement
Piping inspection and testing method
Piping Codes/Standards
ASME B31.1 : Power Piping Code (Mainly for power industries)
ASME B31.3 : Process Piping Code (All industries including Oil and Gas,
Petrochem, Fertilizers, Refinery, etc.)
ASME B31.4 : Liquid Transportation Piping Code (Pipeline)
ASME B31.5 : Refrigeration Piping Code
ASME B31.8 : Gas Transmission and Distribution Code (Pipeline)
ASME B31.9 : Building Services Piping Code
ASME B31.11: Slurry Transportation Piping Code
Terminology of Stress
Terminology of Stress & Strain
Stress () = Force / Cross Sectional Area
Strain () = L / L (Longitudinal Strain)
= D / D (Lateral Strain)



Modulus of Elasticity (E) = / ----- Pipe Span Calculation

Terminology of Stress (Contd)
Yield Strength : Max Stress a material can withstand
withthout permanent deformation
Ultimate Tensile Strength : Max stress a material can
withstand before uncontrolled
yielding and breaking
Allowable Stress : To account for uncertainty in loading and
behavior of materials, a factor of safety
was introduced to find allowable stress of
a material
Allowable Stress = Yield Strength (UTS) / Factor of safety
Terminology of Stress (Contd)
Loads & Stresses in Piping:
Loads in Piping
Longitudinal Stress
Circumferential / Hoop Stress
Radial Stress
Axial Stress
Bending Stress
Shear Stress
Loads & Stresses in Piping:
Stresses in Piping (Contd)
Longitudinal Stress
Stress Developed normal to the cross sectional of pipe, caused by
internal pressure
S
l
= PD/4t


Loads & Stresses in Piping:
Stresses in Piping
Circumferential / Hoop Stress
Stress developed tangential to the cross section of pipe and is due to
internal pressure loading (parallel to pipe circumference)
S
c
= PD/4t
Loads & Stresses in Piping:
Stresses in Piping (Contd)
Radial Stress
Stress developed in radial direction across the wall thickness of pipe.
Its value is equal to internal pressure at the inside of pipe wall and
equal to atmospheric pressure at the pipes external surface

Note At the outer radius of pipe, radial stress is zero whereas the bending
stress is maximum. Hence this stress component has been traditionally
been ignored during stress calculation.
Loads & Stresses in Piping:
Stresses in Piping (Contd)
Axial Stress
Stress developed due to external loads in axial direction in pipe
S
c
= PD/4t

Loads & Stresses in Piping:
Stresses in Piping (Contd)
Bending Stress
Stress developed in pipe due to loads acting in a plane normal to the
axis of pipe. These are due to temperature, weight of pipe, weight of
contents, snow, wind, or earthquake.
S
b
= M/Z

M = Bending Moment
Z = Section Modulus of Pipe
Loads & Stresses in Piping:
Stresses in Piping (Contd)
Shear Stress
Sum of 2 components i.e. Torsional Stress and Direct Shear Stress.
Direct shear stress is negligible (max at neutral axis of pipe and
zero at max distance from neutral axis. Neglected for calculation
because very small)

Torsional Stresses are due to twisting moment on pipe
S
t
= T/2J

T = torque
J = Polar Moment of Inertia

Loads & Stresses in Piping:
Stresses in Piping (Contd)
Distribution of Stresses in Piping
Loads & Stresses in Piping:
Stresses in Piping (Contd)
A Piping System need to accommodate their own expansion
as well as the expansion of connected equipment so as to
avoid:
Failure due to overstress
Leakage at Flange Joints
Distortion of connected equipment
Piping Flexibility
Temperature
COLD
HOT


Not
Flexible
Flexible
More
Flexible
Piping Flexibility (Contd)
A Piping System need to accommodate their own expansion
as well as the expansion of connected equipment so as to
avoid:
Failure due to overstress
Leakage at Flange Joints
Distortion of connected equipment
Methods of Providing Piping
Flexibility
The method to provide flexibility for 2 different types are as
under:

Axial Flexibility
Can be provided by using certain types of bellows

Bending Flexibility
Can be provided using loops, offsets, bends, bellows, etc.
Methods of Providing Piping
Flexibility (Axial Flexibility)
Consider member of cross sectional Area A, length L, and
Modulus of Elasticity E subjected to an axial Load P
Deflection, = PL/AE
Stiffness, k = P/ = AE/L
Axial Flexibility = 1/k = L/AE

Methods of Providing Piping
Flexibility (Bending Flexibility)
Consider the same member is subjected to Bending Load P
Deflection,
b
= PL
3
/CEI
C = Constant depending upon Type of Supports, Loading and
Location of applied Bending Load. For example
Deflection,
b
= PL
3
/48EI, for Simply Supported Beam
Stiffness k = P/
b
= 48EI/L
3

Bending Flexibility = 1/k = L
3
/48EI
Piping Support: Purpose

Carry weight of Pipe, Fittings, Valves, with / without Insulation,
with Operating / Test Fluid
Provide adequate stiffness against external loads like Wind, Ice,
Snow, Seismic Loads etc.
Avoid overstressing of Piping Material
Avoid sagging which creates draining problem
Control Thermal expansion / contraction in the desired manner
Withstand /dampen vibration produced by connected equipment
or Flow induced vibration, Acoustic induced vibration etc.
Pipe Support Span Calculation
(Contd)
Based on Stress
Total Bending Stress (Sustained Load) shall not exceed hot
allowable Stress,
PD/4t + M/Z S
h


For Pipe connection having one end simply supported and
other end fixed,
Bending Moment, M = 5wl
2
/48
Hence Span can be calculated by eq.

PD/4t + 5wl
2
/48Z S
h

Pipe Support Span Calculation
(Contd)
M M
w
l
Pipe Support Span Calculation
(Contd)
Based on Deflection
- For Pipe connection having one end simply supported and
other end fixed,

Maximum Deflection
= wl
4
/128EI
Where,
= Maximum Deflection
E = Modulus of Elasticity
l = Pipe Span
I = Moment of Inertia,
w = Unit weight of Pipe
Pipe Support Span Calculation
(Contd)
l
w

Pipe Support Span Calculation
(Contd)
Based on Free Drain:
For some Pipes with free drain or slope lines, maximum sagging
should be less than the slope of line, hence lower Pipe span is
required
Based on Natural Frequency:
To dampen formation of resonance in vibrating pipe with Natural
frequency of Pipe formed due to Pipe span, the span is adjusted
accordingly

Pipe Support Type
Pipe Support Type (Contd)
Pipe Supports / Hangers:
The main difference between a Hanger and a Support is that the
Hanger sustains the Dead Weight in Tension while the support
does that in compression. Hanger supports pipe from top while
support does it from bottom. Piping Engineer selects support
from Rigid Hangers, Shoes, Trunnion and Flexible Hangers

i. Rigid Hangers:
Used only if Supports are not possible
Used where no vertical movement of Pipe occurs
Used where after pipe movement hanger inclination from vertical direction
is less than 4
Used where no frictional resistance for Thermal growth is desired

Pipe Support Type (Contd)

Shoes
Used for Carrying weight of insulated Pipe
Used where less space is available (w.r.t hanger)
Used where frictional resistance is not a criteria (else slide plates
are used)
Local stress check required where CA>1/8 or wall thickness <
STD (for single web shoe)


Pipe Support Type (Contd)
Trunnion / Dummy Support
Used generally for vertical pipes
Used where clearance between BOD and grade is higher (w.r.t
Shoe)
Used where elbow required to be supported
Local stress check is essential for dummy support

Pipe Support Type (Contd)
Flexible Hanger Variable Spring:
Used for piping with vertical movement but less than 35-40 mm
Used to distribute load when pipe is thermally moving up or down
Used where load variation is less than 25% (from different load
conditions)

% Variability = (Hot Load Cold Load) / Hot Load x 100 = Ky / Hot Load x 100
Pipe Support Type (Contd)
Pipe Support Type (Contd)
Flexible Hanger Variable Spring (Selection):
1) Calculate Piping Load for Spring (Hot Load)
2) Calculate thermal Movement (y) and its direction at that location
3) Locate hot load in load table (preferred at center of table) and
spring suitable for that thermal movement
4) Calculate Installed Load = Hot Load (Thermal Movement [y] x
Spring Rate [k] )
5) Calculate Variability if Hot and Cold or Installed Load in same
column
6) If Variability is within Project Specification (or < 25%) then OK
7) Else move to adjacent column where Hot and Cold load can be
located in working Range
8) Repeat step 3 to 6
9) From Dimension table find length of Spring Assembly
10)Compare with Available clearance
11)If not OK repeat step 3 to 10

Pipe Support Type (Contd)
i. Anchor:
It is a mechanical connection (Welded or Bolted) between
Pipe and Structure
They do not allow movement and rotation of Pipe and
completely fix the line in place
Equipment Nozzles are also anchors but experience thermal
movement
ii. Directional Anchor (Line Stop):
Stops movement of Pipe in axial direction but allow
sideways movement


Pipe Restraint
iii.Guides:
Stops movement of Pipe in sideways direction but allow
axial movement
iv. U - Clamps:
They act as guide or anchor depending on construction and
installation
Used for small bore (less than 2) pipes


Pipe Restraint (Contd)
v. Sway Struts:
It retains movement in one direction while allowing for
movement in another direction
Used where normal Guide or DA is not feasible due to non
availability of Steel Structure
Used where resistance due to friction is not acceptable
Effective under Tensile or Compressive Force
Allows angular motion or misalignment of 5


Pipe Restraint (Contd)

Pipe Restraint (Contd)
vi. Vibration Absorbers Snubbers (Hydraulic):
Used where Pipe experiences vibration due to earthquake,
wind, sudden valve opening/closing, rotating equipment
etc.
It allows slow Thermal growth but resists sudden vibration
It goes to restraint mode based on particular velocity or
acceleration of motion depending on its design called
Activation Level
It consists of Double acting Cylinder and Piston assembly
(A), Flow control Device (B), and Reservoir (C)

Pipe Restraint (Contd)

Pipe Restraint (Contd)
vii.Vibration Absorbers Snubbers (Mechanical):
It utilizes an inertia Mass which generates different
magnitude of resistance force against input Load in
proportion to its acceleration level (M.a = F)
Low input acceleration generates negligible level of
resistance force allowing free movement of Pipe
High input acceleration generates sufficient resistance force
to completely restrain the vibration of Pipe
Mechanical Snubbers are preferred as no Oil Leakage or
change of Oil required

Pipe Restraint (Contd)
Pipe Restraint (Contd)
Pipe Restraint (Contd)
viii.Sway Brace:
It has a pre loaded spring which can be extended or
compressed in order to give increasing resistance in both
direction
The increase in resistance allows it to dampen vibrations on
pipe from equipment, opposes pipe sway and absorbs
Shock Forces

Pipe Restraint (Contd)
Stress Symbol