Int. Journal of Applied Sciences and Engineering Research, Vol. 4, Issue 2, 2015 www.ijaser.

com
2015 by the authors Licensee IJASER- Under Creative Commons License 3.0 editorial@ijaser.com
Research article ISSN 2277 9442

Analysis of piping layout under static load in petrochemical

industries
Senthilkumar G.1, Manikandan H.2, Shanmugasundaram S.3
1,3
Assistant professor-Grade-I, 2Assistant Professor,
Department of Mechanical Engineering,
Panimalar Institute of Technology, Chennai-600123, Tamil Nadu, India.
DOI: 10.6088/ijaser.04024

Abstract: The piping layout used in petrochemical industries taken for the stress analysis. After studying
the critical lines in the layout, the line which is connecting the main distillation unit and air fin cooler is
taken for the analysis. Design of piping layout is interrelated with piping layout and pipe support design
and normally associated with analysis of stresses in a piping system. The functional failure of pipe may
cause accidents, shutdowns and lot of damage to refineries and human beings due to leakage of fluids.
Even under critical conditions like earthquake, heavy fluctuations in wind force the pipe should not fail
and the stresses developed should be within allowable limit. Hence there is a need to carryout stress
analysis of the pipe. In this work using FEA approach hydro, sustain, expansion, occasional load such as
wind load analyses were carried out. These analyses shall be in accordance with the ASME B 31.3.In this
analysis pipe under load is analyzed independently in x, y and z directions and corresponding
displacements, stresses and moments are calculated. The safety of the pipe is verified with respect to
ASME B 31.3. Based on the results obtained in the analyses suitable supporting system is designed. The
results were evaluated using strength of materials theory.

Keywords: Piping layout; stress analysis; displacements; moments; safety standards

1. Introduction

Pipe is a tubular item made of metal, plastic, glass etc. pipe used for transfer fluid from one place to
another place. Piping also includes pipe supporting elements. Its a very important component for any
industrial plant and its engineering plays a major part in overall engineering of plant.

1.1 Pipe stress analysis

This 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, internal and external pressures, changes in fluid flow rate and seismic
activity .Codes and standards establish the minimum requirements of stress analysis. The impact of high
piping stresses on operating piping systems can be dramatic and costly. A thoroughly analyzed plant will
last longer and be more cost effective. Neglecting the impact of the weight of pipe and the thermal
expansion of hot pipe can cause significant maintenance problems such as pump bearings wearing out,

*Corresponding author (e-mail: senthilngt@yahoo.com) 240

Received on November, 2014; Published on February, 2015
 Analysis of piping layout under static load in petrochemical industries

development of hairline cracks in vessels and nozzle junction, leakage of flammable liquids through
flanges, permanent deformation of pipe etc.

1.2 General procedure

The first step in the stress analysis work process is to identify the lines on the critical lines list. Identified
critical line subjected to stress analysis at various node points and joints. More iterations of analysis is
required by changing the routing and providing suitable supports until stress developed is within the
allowable limit. When the stress produced is within the allowable limit then only the pipe routing is
approved.

1.2.1 Various problems encountered in pipeline routing

Various forces act on a pipe from its own weight, thermal growth, wind and other causes. As the forces
applied the piping system begins to deflect or sag. The more forces, the more the pipe deflects. The greater
the pipe deflection, the higher the stress becomes in the pipe material. Once the stress in the pipe reaches a
maximum limit, the deflection becomes permanent. This is called phenomenon yielding. To avoid yielding
a piping component and supporting system during operation should be manipulated.

The second type of problem is overstressing the nozzles. The nozzle itself not the problem, it is the
junction between the nozzle and the vessels wall. As a pipe cycle s from cold to hot to cold again it will
push or pull on the nozzle. Many cycles of the force loading can cause cracking in the vessel wall.

When a piping system pushes a nozzle, the force deflects the linkage between the pump and the pump
motor. Excessive deflection of these linkages causes rapid wear of the bearings and the other parts of the
pump/.this extra wear results in extra maintenance effort on the pump.

1.3 Causes of pipe stress

The most common causes are weight and thermal causes. Weight causes the pipe to sag, which puts stress
into the piping material and forces onto equipment nozzles. Proper spacing and deign of supports and
careful attention to concentrated loads can take care of weight problems.

Figure 1: Flowchart showing stress analysis

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 Analysis of piping layout under static load in petrochemical industries

When a piece of pipe gets hot it grows. The pipe itself physically becomes longer as the temperature of the
pipe material gets hotter. As the pipe grows it pushes against the nozzles and supports that restrain it from
moving. with an improperly stress analyzed system, this pushing will cause pump bearings to wear out
quicker, vessel nozzles to leak ,and perhaps even the pipe or vessels themselves to rupture. Also the
restrain of the growth causes the pipe to deflect in directions different from an unrestrained pipe. This
unnatural deflection causes additional stress in the pipe.

1.4 Wind and earthquake

Wind pushing on a pipe can exert large forces on a piping system. Piping guides and anchors should resist
the wind loading on the piping system. Load due to earthquake also has significant effect on the piping
system. Pulsation loading due to reciprocating compressors is a common stress concern. The back and
forth motion of the compressor pistons compresses the gas .the compressor pushes the gas into the piping
system in pulses. He pulses usually happen around six times a second. This means that the pulsing
frequency is six pulses per second. As a tuning fork has a natural vibrating frequency, every piping system
has a natural vibrating frequency .if the piping system natural frequency is the same as the compressor
pulsing frequency large piping deflection will occur.

1.5 Purpose of stress analysis

The various purposes of stress analysis include ensure the piping is well supported and does not sag or
deflect 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, the stresses in the pipe work in both the hot and cold conditions are below the allowable and
comply with legislation.

1.6 Stresses in piping

1.6.1 Radial stress

Radial stress acts on a line from the center of the pipe; radially through the pipe wall. This stress is
compressive stress acting on the pipe inside diameter caused by internal pressure or a tensile stress caused
by vacuum pressure.

1.6.2 Circumferential stress

Circumferential stress or hoop stress or tangential stress acts on a line perpendicular to the longitudinal and
radial stresses. This stress tends to separate the pipe wall in the circumferential direction and is caused by
internal pressure.
pd
c = N/mm2 (1)
2t
Where, p- Internal pressure in N/mm2, d- Pipe diameter in mm and t- Thickness of pipe in mm

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 Analysis of piping layout under static load in petrochemical industries

1.6.3 Longitudinal stress

The principal stress acting along the center line of the pipe is called a longitudinal stress. The stress is
caused by longitudinal bending, axial force loading or pressure. As a result of the internal pressure, the
cylinder also has a tendency to split into two pieces.
pd
l = N/mm2 (2)
4t
p- Internal pressure in N/mm2, d - Pipe diameter in mm and t - Thickness of pipe in mm

1.6.4 Bending stress

Bending stress is produced due to dead load, thermal expansion or contraction because of temperature
variations, thrust on piping due to blowing wind, thrust on piping due to earthquake.

1.6.5 Torsional stress

This stress also due to thermal expansion or contraction because of temperature variations, thrust on piping
due to blowing wind, thrust on piping due to earthquake

2. Modeling

Plant Design software is a collection of software modules used to design and maintain any type of plant
from petrochemical plants, offshore platforms, chemical and pharmaceutical plants, consumer products, to
power plants, waste water treatment plants.

Table 1: Dimensions

Sl. NO Description Size Material

Pipe Diameter Carbon

1. 250 NB
Steel-ASTM106-A
Pipe Thickness Carbon
2. 9.271mm
Steel-ASTM106-A
Sample Length Carbon
3. 76.7m
Steel-ASTM106-A

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 Analysis of piping layout under static load in petrochemical industries

3. Stress analysis

The one side of the pipe is connected to the main distillation unit and other side is connected to the air fin
cooler. The following loads are considered for static analysis.
Internal fluid pressure of 18 bar
The temperature limits of 110c & 60c
Hydro pressure of 27 bar
Wind speed of 85 mph.
Mill tolerance -12.5 mm
Corrosion allowance 1.5 mm
Youngs modulus (E) = 2.0247x105 N/mm2
Pipe Density () = 7833.4399 kg/m3
Poisons ratio () = 0.2920
Factor of linear expansion () = 1x10-6/c
Fluid density = 970 kg/m3
Insulation density = 100 kg/m3

3.1 Stress Analysis Simulation Results

(a) (b)

(c) (d)

Figure 3: Stress Analysis results a) Overall view of pipe model, b) Finite element model of pipe, c) Finite
element model with hydro load and d) Finite element model with wind load

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 Analysis of piping layout under static load in petrochemical industries

3.2 Stress analysis results

Table 2: Highest Stress Produced Due to Hydro Load

Node Stress Induced Stress Allowable

S.No Type of Stress 2
Point N/mm N/mm2

1 48 Code stress 53.8 217

2 42 Axial stress 22 217

3 48 Bending stress 34.9 217

4 69 Torsion stress 3.2 217

5 28 Hoop stress 39.8 217

Table 3: Highest Stress Produced due to Sustain Load

Stress Stress
Node Type of
S.No Induced Allowable
Point Stress 2
N/mm N/mm2
1 48 Code stress 57.9 137.9

2 42 Axial stress 19.5 137.9

Bending
3 48 42.3 137.9
stress
4 69 Torsion stress 3.8 137.9

5 28 Hoop stress 31.6 137.9

Table 4: Highest Stress Produced due to Thermal Load

(Maximum Temperature)

Stress Stress
S. Node
Type of Stress Induced Allowable
No Point 2
N/mm N/mm2
1 526 Code stress 188.7 206.9
2 523 Axial stress 10.8 206.9
Bending
3 526 188.7 206.9
stress
4 512 Torsion stress 11.5 206.9
5 20 Hoop stress 0 206.9

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 Analysis of piping layout under static load in petrochemical industries

Table 5: Highest Stress Produced due to Thermal Load (Minimum Temperature)

Stress Stress
S. Node Type of
Induced Allowable
No Point Stress 2
N/mm N/mm2
1 526 Code stress 50.3 206.9
2 523 Axial stress 2.9 206.9
Bending
3 526 50.3 206.9
stress
4 512 Torsion stress 3.1 206.9
5 20 Hoop stress 0 206.9

Table 6: Highest Stress Produced due to Wind Load

Stress
S. Node Type of Stress Allowable
Induced
No Point Stress N/mm2
N/mm2
1 526 Code stress 0 183.4
2 20 Axial stress 0 183.4
Bending
3 20 0 183.4
stress
Torsion
4 20 0 183.4
stress
5 20 Hoop stress 0 183.4

Table 7: Highest Stress Produced due to Wind Load and Sustained Load

Stress Stress
S. Node Type of
Induced Allowable
No Point Stress 2
N/mm N/mm2
1 48 Code stress 57.9 183.4
2 42 Axial stress 19.5 183.4
Bending
3 48 42.3 183.4
stress
Torsion
4 69 3.8 183.4
stress
5 28 Hoop stress 31.6 183.4

Table 8: Highest Stress produced due to Sustained Load and Thermal Load (Maximum Temperature)

Stress Stress
S. Node Type of
Induced Allowable
No Point Stress 2
N/mm N/mm2

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 Analysis of piping layout under static load in petrochemical industries

1 526 Code stress 108.4 206.9

2 523 Axial stress 30.3 206.9
Bending
3 526 92.6 206.9
stress
Torsion
4 512 15.3 206.9
stress
5 20 Hoop stress 31.6 206.9

Table 9: Highest Stress Produced due to Sustained Load and Thermal load (Minimum Temperature)

Stress Stress
S. Node Type of
Induced Allowable
No Point Stress 2
N/mm N/mm2
1 526 Code stress 108.4 206.9
2 523 Axial stress 22.4 206.9
Bending
3 526 92.6 206.9
stress
Torsion
4 512 6.9 206.9
stress
5 20 Hoop stress 31.6 206.9

4. Stress analysis-checking criteria

Yield stress (sy) = 1.5 x allowable tensile stress (3)

Sh allowable stress at elevated temperature.
Sc allowable stress at ambient temperature
f Stress reduction factor
Allowable stress range (Sa) = (1.25Sc + 0.25Sh) x f (4)

4.1 Stress evaluation in and out plane bending

(li M i ) 2 + (lo M o ) 2
Sb = (5)
z
li = stress intensity factor in plane
lo = stress intensity factor out plane

Do Di
4 4

z = section modulus = (6)

32 Do

Mt
St = (7)
2 z
2 2
Se = S b + 4 st (8)

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 Analysis of piping layout under static load in petrochemical industries

For safe design Se<=Sa

M
M

Figure 4: Stress Evaluation during bending

4.2 Simplified method to check piping system flexibility

D
If 2
<= K Then piping is
(L U )
flexible (9)

Figure 5: Resultant flexibility diagram

5. Conclusion

Based on the static analysis it is seen that the static loads are well within material yield and endurance
limits. The factor of safety is found to be 4.06 for static conditions which are found to be very safe.

6. References

1. Bausbachen Ed and Roger hunt, Process Plant Layout and Piping Design, Prentice Hall.
2. Munson. D. P and Keever. R. E, Computer Application to the Piping Analysis Requirements,
ASME section III sub article NB-3600.
3. Peng.L.C., 1989, The Art of Checking Pipe Stress Computer Programs, Design and Analysis
of Piping and Components, PVP, p 169.
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 Analysis of piping layout under static load in petrochemical industries

4. Peng.L.C., 1989.Treatment of Support Friction in Pipe Stress Analysis, Design and Analysis
of Piping and Components, PVP, p 169.
5. Roy A. Parisher and Robert A. Rhea, 2002. Pipe Drafting and Design, Gulf Professional
Publishing.
6. Chi-Wen LIN, 1970.Seismic analysis of piping system, Nuclear Engineering and Design, p
196.
7. Myeong-gie-kang, 2000. Natural vibration of a clamped support pipe, Nuclear Engineering
and Design, 196.
8. Glynn E. Woods, Roy P. E and Bagulay. B, 1999. ASME B31.3 Process piping.
9. Wang.X.H and Redekop.D, 2005, Theoritical natural frequencies and mode shapes for curved
pipes, Journal of sound and Vibration, p 292.

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