Stress Analysis
Muhammad Sardar
Declaration of Originality
I hereby declare that the work contained in this thesis and the intellectual content of
this thesis are the product of my own work. This thesis has not been previously
published in any form nor does it contain any verbatim of the published resources
which could be treated as infringement of the international copyright law.
I also declare that I do understand the terms ‘copyright’ and ‘plagiarism’ and
that in case of any copyright violation or plagiarism found in this work, I will be held
fully responsible of the consequences of any such violation.
Signature:
Date:____________________
Certificate of Approval
This is to certify that the work contained in this thesis entitled
“Design of Steam Piping including Stress Analysis”
was carried out by
Muhammad Sardar
Under my supervision and that in my opinion, it is fully adequate, in
scope and quality, for the degree of M.S. Mechanical Engineering from
Pakistan Institute of Engineering and Applied Sciences (PIEAS).
Approved By:
Signature: ________________________
Signature: _______________________
Co-Supervisor: Muhammad Younas, S.E. (DTD, Islamabad)
Signature: ________________________
Co-Supervisor: Hafiz Laiq-ur-Rehman, J.E. (PIEAS, Islamabad)
Verified By:
Signature: ________________________
Head, Department of Mechanical Engineering
Stamp:
v
Dedication
Acknowledgement
First of all I am humbly thankful to Allah Almighty, giving me the power to think and
enabling me to strengthen my ideas. I glorify ALMIGHTY ALLAH for HIS
unlimited blessings and capabilities that HE has bestowed upon me, without HIS
blessings, I would not be able to complete my work. I offer my thanks to Holy
Prophet (Peace Be Upon Him), “The mercy for all the worlds” and whose name has
given me special honor and identity in life.
I am very grateful to my project supervisor Mr. Basil Mehmood Sham, P.E. for his
guidance for the completion of this work. I am also grateful to my co-supervisors
Mr. Muhammad Younas, S.E. and Mr. Hafiz Laiq-ur-Rehman, J.E. for their
inspiring guidance, constant encouragement and fruitful suggestions. At the end I am
also thankful to Engr. Dr. Mohammad Javed Hyder for his keen interest in the
project and constructive criticism, which enabled me to complete my report.
Muhammad Sardar
vii
Table of Contents
1 INTRODUCTION................................................................................................1
5 SUPPORT DESIGN...........................................................................................25
7 THERMAL CALCULATIONS........................................................................56
10 CONCLUSIONS ................................................................................................99
REFERENCES.........................................................................................................101
APPENDIXE ............................................................................................................101
VITA..........................................................................................................................113
xi
List of Figures
Figure 1-1 PFD of the complete piping net work ........................................................4
Figure 2-1 Full loop ....................................................................................................8
Figure 2-2 Z, L and U shaped loop .............................................................................9
Figure 2-3 Anchor support ........................................................................................10
Figure 2-4 Hanger support ........................................................................................10
Figure 2-5 Sliding support ........................................................................................10
Figure 2-6 Spring support .........................................................................................11
Figure 2-7 Snubber support .......................................................................................11
Figure 2-8 Roller support ..........................................................................................11
Figure 5-1 Effective length constants table ..............................................................28
Figure 6-1 Forces on the bend by the fluid ................................................................53
Figure 7-1 Header Pipe including an expansion loop................................................56
Figure 7-2 Header Pipe Sections................................................................................57
Figure 7-3 Symmetry of header pipe considering as a beam.....................................68
Figure 7-4 Segment A-B............................................................................................69
Figure 7-5 Segment A-B-C........................................................................................69
Figure 7-6 Shear Force Diagram................................................................................70
Figure 7-7 Bending Moment Diagram.......................................................................71
Figure 7-8 Loaded view of the meshed beam............................................................72
Figure 7-9 Deflection in Pipe....................................................................................73
Figure 7-10 Bending stress in Pipe .............................................................................73
Figure 8-1 Uniformly load distributed Cantilever Beam...........................................77
Figure 8-2 Double Cantilever beam...........................................................................79
Figure 8-3 Deformed Shape of the beam ..................................................................80
Figure 8-4 Bending Moment diagram of the beam ...................................................81
Figure 8-5 Max. Stress distribution Diagram ...........................................................81
Figure 8-6 Loads on column of the support...............................................................82
Figure 8-7 Meshed and loaded column......................................................................88
Figure 8-8 Deformation of the column .....................................................................88
Figure 8-9 Stress distribution in column ...................................................................89
Figure 8-10 Base Plate Dimensions.............................................................................90
Figure 8-11 Pressure diagram ......................................................................................91
xii
List of Tables
Table 3-1 Primary stresses of pipes ...........................................................................17
Table 3-2 Secondary stresses of pipes .......................................................................18
Table 5-1 Limitation of column slenderness ratio .....................................................28
Table 6-1 Characteristics of Fluid at inlet and out let of pipes and its sizing............30
Table 6-2 Material Properties ....................................................................................32
Table 6-3 Input Parameters used in pipe thickness calculation .................................33
Table 6-4 All pipes thickness along with standard thickness ....................................34
Table 6-5 Input data ...................................................................................................36
Table 6-6 Design and working Pressure ....................................................................36
Table 6-7 Wind loads for each pipe...........................................................................38
Table 6-8 Pipe, Fluid and insulation weights.............................................................40
Table 6-9 Pipe Span based on limitation of stress .....................................................43
Table 6-10 Spacing based on standard spacing ...........................................................45
Table 6-11 Thermal deflection for pipes complete segments......................................47
Table 6-12 Sizing of expansion loops..........................................................................50
Table 6-13 Input Data ..................................................................................................53
Table 6-14 Input data ...................................................................................................54
Table 7-1 Input Data ..................................................................................................56
Table 7-2 For main line magnitude of expansion and directions...............................58
Table 7-3 Vertical section magnitude of expansion and direction ............................58
Table 7-4 Summary of all Loads due to Thermal expansion.....................................66
Table 7-5 Input data ...................................................................................................67
Table 7-6 Input data ...................................................................................................71
Table 7-7 Comparison of analysis for beam ..............................................................74
Table 7-8 Input data ...................................................................................................76
Table 8-1 Available loads for analysis of anchor support .........................................77
Table 8-2 Properties of the channel beam..................................................................78
Table 8-3 Comparison of analysis for beam ..............................................................82
Table 8-4 Specifications of column ...........................................................................83
Table 8-5 Input data ...................................................................................................86
Table 8-6 Input data ...................................................................................................87
xiv
Abstract
This report is about the design of steam piping and its stress analysis of a
given process flow diagram. The prime objective of this project is to design
the piping system and then to analyze its main components. Wall thicknesses
are calculated for all pipes which were found very safe for the operating
pressure. For header pipe the calculated wall thickness is 0.114 inch and the
standard minimum wall thickness is 0.282 inch which is greater than the
calculated one by more than 2.4 times. Different loads such as static loads,
occasional loads and thermal loads of all pipes were also calculated. After
load calculations, spacing of supports and designing of expansion loops were
carried out. Thermal, static and seismic analysis of main system pipe has
been done and results were compared with ASME Power Piping Code B31.1.
After calculation of all applied loads, anchor support components including
half channel beam C5 x 9 and standard circular column of 4 inch nominal size
were designed and analyzed both manually and on ANSYS software. Base
plate of size 15x15x1/4 inch and bolts of ¾ inch diameter and of length 20
inch were also designed. The results obtained from both methods were
compared and found safe under available applied loads.
1
1 Introduction
1.1 Thesis Introduction
Piping System design and analysis is a very important field in any process and power
industry. Piping system is analogous to blood circulating system in human body and is
necessary for the life of the plant. The steam piping system, mentioned in the thesis
will be used for supplying steam to different locations at designed temperature and
pressure. This piping system is one of the major requirements of the plant to be
installed.
I. Sustained loadings which act on the piping system during its operating time
e.g. static loads including dead loads, thermal expansion loads, effects of
supports and internal and external pressure loading.
II. Occasional loads which act percentages of the system’s total operating time
e.g. impact forces, wind loads, seismic loads and discharge loads etc.
While piping stress analysis is used to ensure:
Chapter 8
This chapter consists on the piping support design calculations, in which selection and
analysis of beam, column, base plate and bolts has been done.
Chapter 9
This chapter contained full modeling of anchor support in Pro-E and ANSYS and its
analysis in ANSYS.
4
In the 1920s, the introduction to meet the electrical demand of turbine plants
with super heated steam at temperature up to 600oF and gauge pressure of 300 psi
posed to the next major piping system design challenge. These design conditions
exceeded safe cast iron values, thus requiring the introduction of cast steel for critical
components. By 1924, the steam gauge pressure had increased to 600 psi, doubling in
just a few years. One year later, steam pressure and temperature of 1200 psi and
700oF were achieved, demonstrating the advances made in the development of steam
generator and attached piping. By 1957, some 900oF designs were in service with
1200oF designs projected, using austenitic stainless steel materials in the high
temperature zones, currently, the top gauge pressure is 2400 psi for most fossil fuel
plants. With new materials available, the boiler, turbine and piping have equal
strength capabilities [3].
6
2.2.1 Pipe
“A pipe is a closed conduit of circular cross section which is used for the
transportation of fluids”. If pipe is running full, then the flow is under pressure and if
the pipe is not running full, then the flow is under gravity.
Pressure Pipe: It is used for liquid, gas or vapor for high pressure and temperature
application.
Line Pipe: Threaded or Plain ends used for gas, steam and as an oil pipe.
Water Well: Pump pipe, turbine pipe and driven well pipe etc [1].
For example, NPS 2 indicates a pipe whose outside diameter is 2.375 in [2].
2.2.5 Piping
Pipe sections when joined with fittings, valves, and other mechanical equipment and
properly supported by hangers and supports, are called piping.
7
2.3.1 Valves
A valve is a mechanical device that controls the flow of fluid and pressure within a
system. There are different types of valves some of them are discussed below [3].
a) ON/OFF Valves
These are the kind of valves which are used to stop of start the fluid flow e.g. Gate
valve, Globe valve, rotary ball valve, Plug valve and diaphragm valve etc.
b) Regulating Valve
These are the kind of valves which are used to start, stop and also to regulate the fluid
flow e.g. Needle valve, butterfly valve, Diaphragm and Gate valve etc.
c) Safety Valve
This valve reacts to excessive pressure in piping system. They provide a rapid means
of getting rid of that pressure before a serious accident occur. Safety valve is used
normally for gasses and steams. In safety valve the steam is discharge to the air
through a large pipe.
8
2.4 Supports
Pipe support specifications for individual projects must be written in such a way as to
ensure proper support under all operating and environmental conditions and to
provide for slope, expansion, anchorage, and insulation protection. Familiarity with
standard practices, customs of the trade, and types and functions of commercial
component standard supports and an understanding of their individual advantages and
limitations, together with knowledge of existing standards, can be of great help in
achieving the desired results [1]. Good pipe support design begins with good piping
design and layout. For example, other considerations being equal, piping should be
routed to use the surrounding structure to provide logical and convenient points of
support, anchorage, guidance, or restraint, with space available at such points for use
of the proper component. Parallel lines, both vertical and horizontal, should be spaced
sufficiently apart to allow room for independent pipe attachments for each line. There
are different types of supports used in the piping system; some of them are discussed
below [2].
a) Anchor support
A rigid support providing substantially full fixity for three translations and
rotations about three reference axes. Figure 2-3 shows the model along with
10
the pipe and welding positions. Detail of this support will be discussed in
chapter 8.
d) Spring support
Spring support is used when there is an appreciable difference b/w operating
and non operating conditions of the pipes. Constant load support is used when
loading condition change up to 6%.
used for the design of commercial power and industrial piping system. This section
has the following sub section [1].
mentioned above, so this is the reason that why this code is selected for the steam
piping system which is external to the boiler [5].
PDo 0.75i × M A
SL = + ≤ 1.0 S h (3.1)
4t Z
Where
P = Internal Pressure, psi
Do = Out Side diameter of Pipe, in
t = nominal wall thickness, in
Z = Section modulus of pipe, in3
MA = Resultant moment due to loading on cross section due to weight and other
sustained loads, in-lb
Sh = Basic material allowable stress at design pressure, psi
PDo 0.75i ( M A + M B )
+ ≤ KS h (3.2)
4t Z
Where
MB = Resultant moment loading on cross section due to occasional loads, psi
K= Constant factor depend on plant operation time
The rest of the terms are same to above equation.
15
iM C
≤ S A + f ( Sh − S L ) (3.3)
Z
where
f = Stress range reduction factor
Mc =Range of resultant moment due to thermal expansion, in-lb
SA = Allowable stress range for expansion
The rest of the terms are same to above equation.
There are two types of stresses, normal stress and shear stress. The normal
stresses are perpendicular stress on a body and they are directed normal of the surface
of the body. The tensile stresses are “those stress which produces tension in the
material whereas compressive stresses are those stresses which produce the
compression in the material”.
On the other side “shear stress is the force per unit area of shearing plane. The
shear stresses are those stresses which tend parallel plates of the material to slip past
each other”. The strain is the deformation in the dimension a material when it is under
stress. The strain is of two types shear strain and normal strain [3].
This theory states that failure will always occurs, whenever the greatest tensile stress
tends to exceed the uni-axial tensile strength or whenever the largest compressive
stress tends to exceed the uni-axial compressive strength. This theory has been found
to correlate reasonably well with test data for brittle fracture [3]. The maximum
principle stress theory form the basis for piping system governed by ANSI/ASME
B31 and subsection (class2 and class3) of section III of the ASME boiler and pressure
vessel codes [1].
Where on the other side the maximum shear stress theory states that failure of a
piping component occurs when the maximum shear stress exceed the shear stress at
the yield point in a tension test. In tensile test, at yield, σ1= Sy, where σ2 = σ3 = 0. So
yielding in the component occurs when
(σ 1 − σ 3 ) S y
τ max = =
2 2 (3.4)
This theory correlates reasonably well with the yielding of ductile materials [3]. This
maximum shear stress theory forms the basis for piping of subsection NB (calss1) of
ASME section III [1].
secondary, and peak. The limits of these stresses are related to the various failure
modes as follows [3].
The primary stress limits are intended to prevent plastic deformation and bursting.
Primary stresses which are developed by the imposed loading are necessary to satisfy
the equilibrium between external and internal forces and moments of the piping
system. Primary stresses are not self-limiting. Therefore, if a primary stress exceeds
the yield strength of the material through the entire cross section of the piping, then
failure can be prevented only by strain hardening in the material. Thermal stresses are
never classified as primary stresses. They are placed in both the secondary and peak
stress categories [1].
Primary stresses are the membrane, shear or bending stress resulting from imposed
loadings which satisfy the simple laws of equilibrium of internal and external forces
and moments as arranged in table below;
Primary stresses which considerably exceed the yield strength of the piping material
will result in gross distortion or failure [5].
The primary plus secondary stress limits are intended to prevent excessive plastic
deformation leading to incremental collapse. Secondary stresses are developed by the
constraint of displacements of a structure. These displacements can be caused either
by thermal expansion or by outwardly imposed restraint and anchor point movements.
Under this loading condition, the piping system must satisfy an imposed strain pattern
rather than be in equilibrium with imposed forces. Local yielding and minor
18
distortions of the piping system tend to relieve these stresses. Therefore, secondary
stresses are self-limiting [1].
Secondary stresses are self equilibrium stresses which are necessary to satisfy
the continuity of forces within a structure. As contrasted with stresses from sustained
loads, secondary stresses are not a source of direct failure in ductile with only a single
application of load. If the stresses exceed the material yield strength, they cause local
deformation which result in a redistribution of the loading and upper limit of the stress
in the operating condition. If the applied load is cyclic, however these stresses
constitute a potential source of fatigue failure e.g. the secondary stresses due to
different type of loads are given below in Table 3-2, [5].
Piping System
Design
Analysis Support
9 Process 9 Structural Design of Pipes Design
Design 9 Loads And and
9 Lay outing Calculations Expansion Analysis
Loops
In the structural design of pipes, when all the loads are calculated then the required
span is also calculated for supporting the pipes.
P × Do
tm = +A (4.1)
2 × ( S × Eq + P × Y )
Or
tm = t + A (4.2)
where
tm = minimum required wall thickness, inches
t = pressure design thickness, inches
P = internal pressure, psig
Do = outside diameter of pipe, inches
S = allowable stress at design temperature (known as hot stress), psi
A = allowance, additional thickness to provide for material removed in threading,
corrosion, or erosion allowance; manufacturing tolerance (MT) should also
be considered.
Y = coefficient that takes material properties and design temperature into account.
For temperature below 900°F, 0.4 may be assumed.
E q = quality factor.
2( S × Eq ) × t
P= (4.3)
( Do − 2Yt )
where
t = specified wall thickness or actual wall thickness in inches.
For bends the minimum wall thickness after bending should not be less than the
minimum required for straight pipe.
21
π g
Pipe Weight = ρ steel × ( Do 2 − Di 2 ) × (4.4)
4 gc
π g
Fluid Weight = × ρ fluid × ( Di ) 2 × (4.5)
4 gc
Insulation wt. = Insulation factor x ρInsulationx g/gc (4.6)
Where
D0 = Out side diameter of pipe, in
Di = Inside diameter of pipe, in
t = Insulation Thickness depend on the NPS, in
g = Acceleration due to gravity, ft/sec2
gc = Gravitational constants, lbm-ft/ft-sec2
ρSteel = Density of steel, lb/in3
ρfluid = Density of water, lb/in3
ρinsul = Density of Insulation, lb/in3
Insulation factor depends on the thickness of the insulation of the pipe.
For standard air, the expression for the wind dynamic pressure is given below [1]:
P = 0.00256 × V 2 × CD (4.7)
And to calculate the wind dynamic load (lb/ft), the following expression is used [1]:
F = 0.000213 × V 2 × CD × D (4.8)
Where
Expansion(mm) = α × L × ∆T (4.9)
Where
∆L = Length of pipe (m)
Assumptions
0.33ZS h
Ls = (4.10)
w
Based on limitation of deflection [2]
∆EI
Ls = 4 (4.11)
22.5w
Where
Ls = Allowable pipe span, ft
Z = Modulus of pipe section, in3
Sh = Allowable tensile stress at design temperature, psi
w = Total weight of pipe, lb/ft
∆ = Allowable deflection/sag, in
I = Area moment of inertia of pipe, in4
24
3EDo ∆
L= (4.12)
144 S A
Where
L = Length of expansion Loops, ft
E, Do, SA, same as in above calculations
Size of Expansion Loops assuming to be symmetrical U shaped.
L = 2H + W
Where
H = 2W for U shaped loop.
25
5 Support Design
Pipe support specifications for individual projects must be written in such a way as to
ensure proper support under all operating and environmental conditions and to
provide for slope, expansion, anchorage, and insulation protection. Familiarity with
standard practices, customs of the trade, types and functions of commercial
component standard supports and an understanding of their individual advantages and
limitations, together with knowledge of existing standards, can be of great help in
achieving the desired results [3].
Good pipe support design begins with good piping design and layout. For
example, other considerations being equal, piping should be routed to use the
surrounding structure to provide logical and convenient points of support, anchorage,
guidance, or restraint, with space available at such points for use of the proper
component. Parallel lines, both vertical and horizontal, should be spaced sufficiently
apart to allow room for independent pipe attachments for each line. There are
different types of supports used in the piping system e.g. Anchor support, Guide,
hanger, sliding, snubber support etc. The type of support which we will design in this
project is anchor support. It is a rigid support providing substantially full fixity for
three translations and rotations about three reference axes.
This support mainly includes the beam, column, base plate and anchor bolts. So the
design of all these components will be discussed in this chapter [1].
Mc
σb = (5.1)
I
where
M = Bending moment on the cross section, in-lb
c = Distance from neutral axis to point of interest, in
I = Moment of inertia of cross section, in4
The failure mode for bending is material yielding. For this reason the allowable stress
for bending is usually limited to the material stress reduced by a safety factor.
VAy
τ= (5.2)
Ib
where
V = shear force on cross section, lb
A = Cross sectional area, in2
y = Distance from the neutral axis to the centriod of the area, in
I = Moment of inertia of the beam cross section, in4
b = width of the beam, in
The horizontal shear stress is a maximum at the neutral axis of the beam.
This is opposite of the behavior of the bending stress which is maximum at the outer
edge of the beam and zero at the neutral axis.
27
5.1.3 Deflection
The lateral load acting on beam causes the beam to bend, deforming the axis of the
beam into a curve called the deflection of the beam. This deformation of a beam is
most easily expressed in terms of the deflection of the beam from its original
unloaded position. This deflection is measured from the original neutral surface to the
neutral surface of the deformed beam. The deflection in uniformly distributed
cantilever beam can be calculated by using the following equation [3]
− wl 4
ymax = (5.3)
8 EI
Where
y = deflection at point l, in
w = uniformly distributed load, lb/in
l = length at which deflection is to be calculated
E = Modulus of elasticity of the material being used in beam, Mpsi
I = Moment of inertia, in4
5.2 Column
A long slender bar subject to axial compression is called a column. The term column
is frequently used to describe a vertical member. Column may be divided into three
general types: Short columns, Intermediate columns and Long Column. The
compressive capacity of a column is dependent on its slenderness ratio, which is
defined as [3]
Kl
Slenderness ratio = (5.4)
r
Where
K = a constant dependent on boundary conditions
Critical load and critical stress can be find out from the following equations [7]
π 2 EI
Pcr = (5.5)
Leff 2
π 2E
σ cr = 2
(5.6)
⎛ Leff ⎞
⎜ r ⎟⎠
⎝
For column subjected to both axial and bending stress, AISC subsection H1
specification requires that the following equations must be satisfied [7].
29
fa f f
+ bx + by ≤ 1 (5.7)
0.6 Fy Fbx Fby
Also, when fa/Fa < 0.15, following equation can be used,
f a fbx f by
+ + ≤1 (5.8)
Fa Fbx Fby
Where
fa = axial stress in column = P/A
Fa = allowable axial stress
Fb, x/y = Bending stress in x or y direction = Mc/I
Fb, x/y = allowable bending stresses in x or y direction
As already sizing of this piping system has been done and the available
information are;
Number of pipes = 48
Number of junctions = 49
Wind Velocity = 100 miles/hr
Pipe Nominal Size, Inlet-Out let velocities, Temperatures and Pressure of steam for
every pipe are given below in the following Table 6-1.
Table 6-1 Characteristics of Fluid at inlet and out let of pipes and its sizing
Pipe POut
D o, TOut, VIn, Vout Pin
S. No
°
Line NPS TIn, C ° (static)
(in) C m/sec m/sec (static)bar
No. bar
Table 6-1 Characteristics of Fluid at inlet and out let of pipes and its sizing (continued)
Table 6-1 Characteristics of Fluid at inlet and out let of pipes and its sizing (continued)
Pipe Pin POut
S. No D o, ° ° VIn, Vout
Line NPS TIn, C TOut, C (static) (static),
(in) m/sec m/sec
No. bar bar
Physical properties of pipe material, insulation and water are arranged in Table 6-2
below;
P × Do
Design thickness tm = +A (4.1)
2 × ( S × Eq + P × Y )
or
=t+A
Let take Pipe no. 208 and calculate its minimum thickness by using equation.
Where all the parameters are arranged in Table 6-3 below;
tm = 0.09984 In
0.0998
tm =
0.85
tm = 0.12in
tm = 2.9mm
Standard tm = 0.282 in
For all 48 pipes the thickness were calculated and arranged in the Table 6-4 below
along with the standard minimum wall thickness. From the table it is cleared that
nearly 2 to 3 times, so our calculated thickness is safe.
34
Pipe Line
D (in)
Out side Diameter,
(stat.), P (lb/In2)
Design Pressure
(m/sec)
Velocity, Inlet
H=(P/W+V^2/2*g)
Total Head,(m)
Pabs(Psi)= ρ*g*H
Psat-14.7
(gage.), P(lb/In2)=
DesignPressure
S(psi)
Allowable Stresss,
/2*(S+.4*P)
thickness,t(in)=P*D
Min. Wall
allowance, A (in)
Corrosion
thickt(t), (in)
Total min. Wall
T=12.5% (in)
t= (t/1-T)
t(mm)
thickness (in)
Min.Allowable
S.No
No.
1
P-208 8 8.625 117.23 35.37 146.274 208.01 193.31 14400 0.4 0.0605 0.0394 0.0999 0.114 2.903 0.282
2 P-209 2 6.625 114.22 13.98 90.283 128.39 113.69 14400 0.4 0.0274 0.0394 0.0668 0.076 1.940 0.135
3 P-210 8 8.625 114.37 35.27 143.894 204.63 189.93 14400 0.4 0.0595 0.0394 0.0988 0.113 2.872 0.282
4 P-211 8 8.625 110.44 36.46 145.470 206.87 192.17 14400 0.4 0.0602 0.0394 0.0995 0.114 2.892 0.282
5 P-212 8 8.625 107.15 28.15 115.774 164.64 149.94 14400 0.4 0.0470 0.0394 0.0864 0.099 2.510 0.282
6 P-213 4 4.5 105.00 27.78 113.203 160.98 146.28 14400 0.4 0.0239 0.0394 0.0633 0.072 1.839 0.207
7 P-214 8 8.625 104.90 21.61 97.598 138.79 124.09 14400 0.4 0.0389 0.0394 0.0783 0.090 2.275 0.282
8 P-215 6 6.625 106.88 16.28 88.676 126.10 111.40 14400 0.4 0.0268 0.0394 0.0662 0.076 1.924 0.245
9 P-216 2 2.375 106.69 20.79 97.079 138.05 123.35 14400 0.4 0.0107 0.0394 0.0500 0.057 1.454 0.178
10 P-217 4 4.5 106.34 31.60 125.735 178.80 164.10 14400 0.4 0.0268 0.0394 0.0662 0.076 1.924 0.207
11 P-218 3 3.5 104.05 17.70 89.148 126.77 112.07 14400 0.4 0.0143 0.0394 0.0536 0.061 1.559 0.189
12 P-219 4 4.5 58.80 18.15 58.155 82.70 68.00 14400 0.4 0.0111 0.0394 0.0505 0.058 1.468 0.207
13 P-220 4 4.5 103.78 22.01 97.703 138.94 124.24 14400 0.4 0.0203 0.0394 0.0597 0.068 1.735 0.207
14 P-221 2 2.375 101.77 17.99 88.072 125.24 110.54 14400 0.4 0.0096 0.0394 0.0489 0.056 1.422 0.178
15 P-224 4 4.5 101.67 17.56 87.227 124.04 109.34 14400 0.4 0.0179 0.0394 0.0573 0.066 1.664 0.207
16 P-225 2 2.375 100.45 18.07 87.298 124.14 109.44 14400 0.4 0.0095 0.0394 0.0488 0.056 1.419 0.178
17 P-226 3 3.5 100.28 22.18 95.626 135.99 121.29 14400 0.4 0.0154 0.0394 0.0548 0.063 1.593 0.189
18 P-227 2 2.375 99.12 10.95 75.822 107.82 93.12 14400 0.4 0.0081 0.0394 0.0474 0.054 1.378 0.178
19 P-228 3 3.5 98.96 17.43 85.080 120.99 106.29 14400 0.4 0.0135 0.0394 0.0529 0.061 1.538 0.189
20 P-229 2 2.375 98.43 10.26 74.589 106.07 91.37 14400 0.4 0.0079 0.0394 0.0473 0.054 1.374 0.178
21 P-230 2 2.375 29.34 23.95 49.908 70.97 56.27 14400 0.4 0.0049 0.0394 0.0442 0.051 1.286 0.178
22 P-231 1 1.315 29.16 37.41 91.916 130.71 116.01 14400 0.4 0.0055 0.0394 0.0449 0.051 1.305 0.116
23 P-232 3 3.5 98.39 12.81 77.563 110.30 95.60 14400 0.4 0.0122 0.0394 0.0515 0.059 1.498 0.189
24 P-233 2 2.375 97.59 6.94 71.081 101.08 86.38 14400 0.4 0.0075 0.0394 0.0468 0.054 1.361 0.178
25 P-236 1.5 1.9 29.27 23.32 48.327 68.72 54.02 14400 0.4 0.0037 0.0394 0.0431 0.049 1.253 0.127
35
Table 6-4 All pipes thickness along with standard thickness (Continued)
H=(P/W+V^2/2*
thickness,t(in)=P
D.T. Factor (y)
Diameter, D (in)
(stat.), P (lb/In2)
Design Pressure
Pipe Line
le thickness (in)
DesignPressure
Total Head,(m)
Stresss, S(psi)
*D/2*(S+.4*P)
Velocity, Inlet
allowance (in)
Pipe Nominal
T=12.5% (in)
Min.Allowab
thickt(t) (in)
Pabs(Psi)=
t= (t/1-T)
P(lb/In2)=
Min. Wall
Corrosion
Allowable
Psat-14.7
Out side
(gage.),
(m/sec)
ρ*g*H
t(mm)
S.No
Size,
g)
No.
26 P-237 1 1.315 29.27 32.02 72.901 103.67 88.97 14400 0.4 0.0043 0.0394 0.0436 0.050 1.268 0.116
27 P-238 2 2.375 97.40 21.21 91.441 130.04 115.34 14400 0.4 0.0100 0.0394 0.0493 0.056 1.434 0.178
28 P-239 1 1.315 94.34 21.74 90.466 128.65 113.95 14400 0.4 0.0055 0.0394 0.0448 0.051 1.303 0.116
29 p-240 2 2.375 94.30 16.06 79.478 113.02 98.32 14400 0.4 0.0085 0.0394 0.0479 0.055 1.391 0.178
30 P-241 1 1.315 92.67 29.15 108.524 154.33 139.63 14400 0.4 0.0067 0.0394 0.0460 0.053 1.338 0.116
31 P-242 2 2.375 92.80 8.63 69.054 98.20 83.50 14400 0.4 0.0072 0.0394 0.0466 0.053 1.354 0.178
32 P-243 2 2.375 100.25 5.52 72.050 102.46 87.76 14400 0.4 0.0076 0.0394 0.0470 0.054 1.365 0.178
33 P-244 1 1.315 92.27 11.43 71.549 101.75 87.05 14400 0.4 0.0042 0.0394 0.0435 0.050 1.265 0.116
34 P-250 3 3.5 58.80 12.28 49.046 69.75 55.05 14400 0.4 0.0070 0.0394 0.0464 0.053 1.348 0.189
35 P-251 1 1.315 58.33 29.53 85.499 121.59 106.89 14400 0.4 0.0051 0.0394 0.0445 0.051 1.293 0.116
36 P-252 2 2.375 58.54 19.58 60.724 86.35 71.65 14400 0.4 0.0062 0.0394 0.0456 0.052 1.324 0.178
37 P-253 1.5 1.9 57.15 16.82 54.626 77.68 62.98 14400 0.4 0.0044 0.0394 0.0437 0.050 1.271 0.127
38 P-254 1 1.315 56.77 37.37 111.180 158.11 143.41 14400 0.4 0.0069 0.0394 0.0462 0.053 1.343 0.116
39 P-256 2 2.375 58.80 37.39 112.691 160.25 145.55 14400 0.4 0.0126 0.0394 0.0519 0.059 1.509 0.178
40 P-257 6 6.625 58.80 21.55 65.042 92.49 77.79 14400 0.4 0.0188 0.0394 0.0581 0.067 1.690 0.245
41 P-259 3 3.5 29.40 27.66 59.703 84.90 70.20 14400 0.4 0.0089 0.0394 0.0483 0.055 1.404 0.189
42 P-260 3 3.5 29.40 27.50 59.258 84.27 69.57 14400 0.4 0.0089 0.0394 0.0482 0.055 1.402 0.189
43 P-261 3 3.5 22.05 20.90 37.781 53.73 39.03 14400 0.4 0.0050 0.0394 0.0443 0.051 1.289 0.189
44 P-262 3 3.5 29.40 15.23 32.510 46.23 31.53 14400 0.4 0.0040 0.0394 0.0434 0.050 1.261 0.189
45 P-263 2 2.375 29.40 22.37 46.194 65.69 50.99 14400 0.4 0.0044 0.0394 0.0438 0.050 1.272 0.178
46 P-264 2 2.375 29.40 17.26 35.877 51.02 36.32 14400 0.4 0.0031 0.0394 0.0425 0.049 1.236 0.178
47 P-270 3 3.5 44.10 28.44 72.267 102.77 88.07 14400 0.4 0.0112 0.0394 0.0506 0.058 1.470 0.189
48 P-271 1 1.315 14.70 24.31 40.496 57.59 42.89 14400 0.4 0.0021 0.0394 0.0414 0.047 1.204 0.116
36
the standard thickness to find the maximum pressure that the pipe material can
2( S × Eq ) × t
P= (4.3)
( Do − 2Yt )
Let take Pipe no. 208 and calculate its minimum thickness by using Table 6-5.
S.No
NPS, Pressure (gage)
Pipe Line No. Do (in) Allowable Pressure psi
in psi
Total
Pipe N Insul. Insul.
S. Pipe wt., Fluid static
Line L, (ft) P Thick XInsul wt.
No (lbs) wt.(lbs) Loads
No. S (In) (lb)
(lbs)
1 P-208 262 8 3.15 0.97 10.369 7450.18 5680.53 13141.08
2 P-209 16 2 1.97 0.21 0.137 58.21 23.27 81.61
3 P-210 394 8 3.15 0.97 15.593 11203.71 8542.47 19761.78
4 P-211 341 8 3.15 0.97 13.495 9696.61 7393.36 17103.47
5 P-212 361 8 3.15 0.97 14.287 10265.33 7826.99 18106.60
6 P-213 787 4 2.56 0.39 12.523 8456.94 4342.05 12811.51
7 P-214 16 8 3.15 0.97 0.633 454.97 346.90 802.51
8 P-215 16 6 3.15 0.83 0.542 302.33 200.33 503.21
9 P-216 98 2 1.97 0.21 0.840 356.51 142.52 499.87
10 P-217 164 4 2.56 0.39 2.610 1762.31 904.82 2669.74
11 P-218 16 3 1.97 0.25 0.163 120.71 51.26 172.14
12 P-219 9.8 4 2.56 0.39 0.156 105.31 54.07 159.53
13 P-220 279 4 2.56 0.39 4.439 2998.08 1539.30 4541.82
41
Total
Pipe N Insul.
S. Insul. Pipe wt., Fluid static
Line L, (ft) P Thick XInsul
No wt. (lb) (lbs) wt(lbs) Loads
No. S . (In)
(lbs)
Let take Pipe no. 208 and calculate span limitation for it by using the data from Table
6-1 and 6-8.
L = 262 ft (From Table 6-1)
Z = 16.8 in3 (Appendix Table A2)
Sh = 14400 ksi (Appendix Table A1)
w = 50.15 lb/ft (From Table 6.8)
262 × 12
Expansion(mm)=14.9×10-3 × ×169.7=204.16mm
39.37
These calculations are arranged for all 48 pipes in the Table 6-11 below.
(α) =
S. Pipe TIn, o ∆T Deflection Deflection
L, ft o Tout , C o (mm*10
No Line No. C ( C) -3 o ∆(mm) ∆(m)
/m C)
1 P-208 262 169.70 168.80 169.70 14.9 204.16 0.20
P-208-1 200 169.70 169.20 169.70 14.9 154.18 0.15
P-208-2 65 169.00 168.80 169.00 14.9 49.90 0.05
2 P-209 16 169.00 168.30 169.00 14.9 12.28 0.01
3 P-210 394 168.80 167.50 168.80 14.9 302.12 0.30
P-210-1 200 168.80 168.10 168.80 14.9 153.36 0.15
P-210-2 194 168.10 168.00 168.10 14.9 148.14 0.15
4 P-211 341 167.50 166.30 167.50 14.9 259.47 0.26
P-211-1 200 167.50 166.90 167.50 14.9 152.18 0.15
P-211-2 141 166.90 166.50 166.90 14.9 106.90 0.11
5 P-212 361 166.40 165.20 166.40 14.9 272.88 0.27
P-212-1 200 166.40 165.80 166.40 14.9 151.18 0.15
P-212-2 161 165.80 165.50 165.80 14.9 121.26 0.12
6 P-213 787 165.20 158.30 165.20 14.9 590.61 0.59
P-213-1 200 165.20 165.00 165.20 14.9 150.09 0.15
P-213-2 200 165.00 164.00 165.00 14.9 149.91 0.15
P-213-3 200 164.00 163.00 164.00 14.9 149.00 0.15
48
(α) =
S. Pipe TIn, o ∆T Deflection Deflection
L, ft o Tout , C o (mm*10
No Line No. C ( C) -3 o ∆(mm) ∆(m)
/m C)
P-213-4 187 163.00 162.00 163.00 14.9 138.47 0.14
7 P-214 16 165.30 165.20 165.30 14.9 12.01 0.01
8 P-215 16 166.50 166.40 166.50 14.9 12.10 0.01
9 P-216 98 166.40 163.40 166.40 14.9 74.08 0.07
10 P-217 164 166.20 164.90 166.20 14.9 123.82 0.12
11 P-218 16 165.10 164.70 165.10 14.9 12.00 0.01
12 P-219 9.8 158.00 157.90 158.00 14.9 7.03 0.01
13 P-220 279 165.00 161.80 165.00 14.9 209.12 0.21
P-220-1 200 165.00 163.40 165.00 14.9 149.91 0.15
P-220-2 79 162.00 161.80 162.00 14.9 58.14 0.06
14 P-221 230 161.80 154.40 161.80 14.9 169.05 0.17
P-221-1 200 161.80 160.00 161.80 14.9 147.00 0.15
P-221-2 30 160.00 154.40 160.00 14.9 21.80 0.02
15 P-224 262 161.80 158.30 161.80 14.9 192.57 0.19
P-224-1 200 161.30 160.00 161.30 14.9 146.55 0.15
P-224-2 62 160.00 159.00 160.00 14.9 45.06 0.05
16 P-225 197 158.30 152.10 158.30 14.9 141.66 0.14
17 P-226 115 158.20 156.70 158.20 14.9 82.65 0.08
18 P-227 525 156.80 133.50 156.80 14.9 373.95 0.37
P-227-1 200 156.80 156.50 156.80 14.9 142.46 0.14
P-227-2 200 150.00 147.80 150.00 14.9 136.28 0.14
P-227-3 125 135.00 133.50 135.00 14.9 76.66 0.08
19 P-228 82 156.70 155.50 156.70 14.9 58.37 0.06
20 P-229 164 155.50 147.90 155.50 14.9 115.85 0.12
21 P-230 164 135.20 124.80 135.20 14.9 100.72 0.10
P-230-1 100 135.20 129.20 135.20 14.9 61.42 0.06
P-230-2 64 129.20 124.80 129.20 14.9 37.56 0.04
22 P-231 115 135.00 120.10 135.00 14.9 70.53 0.07
23 P-232 246 155.50 150.50 155.50 14.9 173.77 0.17
P-232-1 200 154.30 153.00 154.30 14.9 140.19 0.14
24 P-233 131 150.50 141.30 150.50 14.9 89.56 0.09
25 P-236 98 127.90 118.50 127.90 14.9 56.94 0.06
26 P-237 66 127.70 119.50 127.70 14.9 38.29 0.04
27 P-238 213 150.40 145.70 150.40 14.9 145.53 0.15
P-238-1 200 148.00 147.30 148.00 14.9 134.46 0.13
P-238-2 13 147.30 145.70 147.30 14.9 8.70 0.01
28 P-239 197 145.70 131.30 145.70 14.9 130.39 0.13
29 p-240 180 145.80 140.90 145.80 14.9 119.22 0.12
P-240-1 100 145.80 143.30 145.80 14.9 66.23 0.07
P-240-2 80 143.30 140.90 143.30 14.9 52.08 0.05
30 P-241 262 140.70 126.00 140.70 14.9 167.46 0.17
P-240-1 200 140.70 136.00 140.70 14.9 127.83 0.13
49
(α) =
S. Pipe TIn, Tout , ∆T Deflection Deflection
L, ft o o o (mm*10
No Line No. C ( C) ( C) -3 o ∆(mm) ∆(m)
/m C)
31 P-242 197 140.90 131.60 140.90 14.9 126.09 0.13
32 P-243 262 131.70 114.10 131.70 14.9 156.75 0.16
P-243-1 200 131.70 122.40 131.70 14.9 119.65 0.12
P-243-2 62 117.50 114.10 117.50 14.9 33.09 0.03
33 P-244 394 131.62 95.90 131.62 14.9 235.58 0.24
P-244-1 200 131.62 120.62 131.62 14.9 119.58 0.12
P-244-2 94 100.30 95.90 100.30 14.9 42.83 0.04
34 P-250 6.6 160.20 159.90 160.20 14.9 4.80 0.00
35 P-251 328 159.70 122.20 159.70 14.9 237.95 0.24
P-251-1 200 159.70 145.70 159.70 14.9 145.09 0.15
P-251-2 128 139.40 122.20 139.40 14.9 81.06 0.08
36 P-252 115 159.90 153.80 159.90 14.9 83.53 0.08
37 P-253 66 153.80 147.60 153.80 14.9 46.11 0.05
38 P-254 197 153.50 133.30 153.50 14.9 137.37 0.14
39 P-256 230 156.20 150.40 156.20 14.9 163.20 0.16
P-256-1 200 156.20 153.30 156.20 14.9 141.91 0.14
P-256-2 30 153.30 150.40 153.30 14.9 20.89 0.02
40 P-257 33 153.10 152.80 153.10 14.9 22.95 0.02
41 P-259 164 142.80 137.80 142.80 14.9 106.39 0.11
42 P-260 39 140.50 139.10 140.50 14.9 24.89 0.02
43 P-261 49 119.20 117.30 119.20 14.9 26.53 0.03
44 P-262 16 136.10 135.30 136.10 14.9 9.89 0.01
45 P-263 16 129.10 127.90 129.10 14.9 9.38 0.01
46 P-264 49 120.40 116.80 120.40 14.9 26.80 0.03
47 P-270 262 157.70 152.70 157.70 14.9 187.69 0.19
P-270-1 200 157.70 155.20 157.70 14.9 143.28 0.14
P-270-2 62 153.40 152.20 153.40 14.9 43.20 0.04
48 P-271 33 157.80 152.70 157.80 14.9 23.66 0.02
3EDo ∆
L= (6.2)
144 S A
Take Pipe no. 208 and calculating thermal expansion in it by using Equation (4.9).
L = 200 ft = 60.98 m (section of length 262 ft)
∆T = 169°C (operating temp - non operating temp)
α = 14.9 x 10-3 (mm/m C°) (Appendix Table A6)
50
For the first time considering the fluid is flowing at its highest speed V1 and highest
pressure P1, so that for shock loading assuming V2 = 0. To find the force in horizontal
direction, using the impulse momentum equation given below [8].
∑F x = P1 A1 − P2 A2 cos θ − ( FB ) x = m × (V2 − V1 )
F
(6.4)
All the in put data are arranged for above equation in Table 6-13.
Table 6-13 Input Data
( FB ) x = 12.994kips
F
Similarly finding the force in x- direction, using impulse momentum equation below
[8],
( FB ) y = 14.7 × 50.03
F
( FB ) y = 735.44lb
F
( FB ) = ( FB ) x 2 + ( FB ) y 2
F F F
( FB ) = 13.014kips
F
g
P2 = P1 − ( Z1 − Z 2 ) × ρ (6.6)
gc
Table 6-14 Input data
Using Equation (6.6) and obtaining the value of pressure at outlet of the expansion
loop.
32.17
P2 = 193.3 − 12 × 0.0361 ×
32.17
P2 = 192.868 psi
Using Equation (6.4) for force in x-direction,
∑F x = P1 A1 − P2 A2 cos θ − ( FB ) x = m × (V2 − V1 )
F
(6.4)
( FB ) x = 9.67lb
F
As V1 = V2 and P1A1 sin (θ) = 0, for θ = 0o therefore the above equation becomes:
( FB ) y = P2 × A2
F
( FB ) y = 9.643lb
F
( FB ) = ( FB ) x 2 + ( FB ) y 2
F F F
( FB ) = (9.67) 2 + (9.643) 2
F
( FB ) = 13.65lb
F
θ = 450
For shock loading the value of load is greater than that of the value of the load at
normal operation, therefore for the verse condition shock load will be consider to
analyze the support.
56
7 Thermal Calculations
Based on spacing calculated above considering header pipe P-208 of length segment
200ft. At both side of this expansion loop there are anchor supports and eight guided
supports equally spaced at length 22.22 ft. This expansion loop will be further
analyzed for thermal and static loads.
For thermal analysis, using the data from Table 6-1, 6-11, Appendix A-2 and A-3,
and arranging it in Table 7-1 given below.
Thermal Load
12 × E × I × ∆
F = (7.1)
L3
57
6× E× I× ∆
Moment: M = (7.2)
L2
Where
∆ = Thermal Expansion, in
L = Length of segment under observation, in
E = Modulus of Elasticity, psi
I = Section modulus, in3
Total Displacement absorbed by a section of pipe [3]:
Ln 3∆ T
∆n = (7.3)
ΣL i 3
Where
Considering 200 feet segment of pipe no. 208 and then taking its half symmetry for
analysis by assuming the pipe segments to be straight and acts just a cantilever beam.
As shown in figure the header pipe no. 208 has been divided into different sections.
As this pipe has two main sections, one is the main line and the other is vertical leg
which is perpendicular to the main line, so the nomenclature of the piping section as
given below:
Main line including the segments A-B, B-C, C-D, D-E = 22.22 ft, E-F= 7.1 ft
F-G = 16 ft
58
σ t = E × α × ∆T (7. 4)
Where
∆n = Ln3∆T/ΣLi3 (7.3)
163 × 2.17
∆x =
163
∆x = 2.17in
12EI∆
Fx= (7.1)
L3
∆ = 2.17 in
12×27.5×106 ×72.5×2.17
Fx=
(16×12)3
Fx=7335lb
Ln = LAF = 96 ft
Li = 96 ft,
∆T = 0.3616 in
963 × 0.3616
∆y =
963
∆y = 0.3616in
Fy across A-F
∆y = 0.3616 in
12 × E × I × ∆
F = (7.1)
L3
12×27.5×106 ×72.5×.3616
Fy=
(96×12)3
Fy=5.65lb
6EI∆
Mz= (7.2)
L2
6×27.5×106 ×72.5×0.3616
Mz=
(96×12) 2
Mz=3259.5lb-in
(∆y,total ) = 0.3616 in
LAC = 44.44 ft
61
LAF = 96 ft
0.36166 × 44.44
∆y, B −C =
96
∆y, B −C = 0.167in
12 × E × I × ∆
F = (7.1)
L3
Modulus of Elasticity (E) = 27.5 x 106 psi
Moment of Inertia (I) = 72.5 in4
L = 22.22 ft = 266.64 in
12×27.5×106 ×72.5×0.167
Fy,B-C =
266.643
Fy,B-C =210.76lb
6× E× I× ∆
M = (7.2)
L2
Mz,B-C =28.098×103 lb-in
For section C-D
12 × E × I × ∆
F = (7.1)
L3
Modulus of Elasticity (E) = 27.5 x 106 psi
Moment of Inertia (I) = 72.5 in4
62
L = 22.22 ft = 266.64 in
12×27.5×106 ×72.5×0.251
Fy,C-D =
266.643
Fy,C-D =316.78lb
6× E× I× ∆
M = (7.2)
L2
Mz,C-D =42.232×103 lb-in
For section D-E
(∆y,total ) = 0.3616 in
LAE = 88.88ft
LAF = 96 ft
0.3616×88.88
∆y,D-E =
96
∆y,D-E =0.3348in
And similarly using Equation (7.1) for force in section E-F and Equation (7.2) for
thermal moment
12×27.5×106 ×72.5×0.3616
Fy,E-F =
266.643
Fy,E-F =455.6lb
Mz,E-F =60.74×103 lb-in
Fy,A =105.633lb
Mz AB Mz BC
Fy,B =Fy,A + + (7.5)
L AB L BC
14082 28098
Fy,B =105.633+ +
266.64 266.64
Fy,B =264.62lb
Similarly using Equation (7.5) for supports C, D, and E in the same way as above,
28098 42232
Fy,C =210.76+ +
266.64 266.64
Fy,C =474.52lb
42232 56200
Fy,D =421.52+ +
266.64 266.64
Fy,D =792.26lb
56200 60740
Fy,E =455.6+ +
266.64 266.64
Fy,E =895.78lb
64
16 3 × 2.17 in
∆x across AF = 16 3
= 2.17 in
(∆y,total ) = 0.3616 in
LAB = 22.22 ft
LAF = 96 ft
2.17 × 22.22
∆x, A− B =
96
∆x, A− B = 0.50in
(∆y,total ) = 0.3616 in
LAC = 44.44 ft
65
LAF = 96 ft
2.17 × 44.44
∆x, B −C =
For Section B-C 96
∆x, B −C = 1.004in
(∆y,total ) = 0.3616 in
LAD = 66.66 ft
LAF = 96 ft
2.17 × 66.66
∆x,C − D =
For section C-D 96
∆x,C − D = 1.5in
2.17×88.88
∆x,D-E =
96
∆x,D-E =2.00in
For section D-E
12×27.5×106 ×72.5×2
Fx,D-E =
266.643
Fx,D-E =2524.1lb
2.17×96
∆x,E-F =
96
∆x,E-F =2.17in
For section D-E
12×27.5×106 ×72.5×2.17
Fx,E-F =
266.643
Fx,E-F =2738.645lb
Fx,B =
( FA-B +FB-C ) (7.6)
2
Fx,B =(631+1267)/2=949lb
And similarly for support C, D and E using Equation (7.6)
Fx,C =(1267+1893)/2=1580lb
Fx,D =(1893+2524.1)/2=2208.5lb
Fx,E =(2524.1+2738.643)/2=2631.4lb
All the resultants loads are arranged in Table 7-4 below,
iM C
≤ S A + f (Sh − SL ) (7.7)
Z
Where
f = Stress range reduction factor
Mc =Range of resultant moment due to thermal expansion, in-lb
SA = Allowable stress range for expansion, psi
Z = Section modulus of pipe, in3
Sh =Basic material allowable stress at design pressure, psi
i = stress intensification factor
These all values are arranged in Table 7-5 below,
Equation (7.7), after putting values from above table gives the following comparison;
1 × 60740
≤ 21400 + 1 × (14400 − 1297.098)
16.8
4.032 × 103 ≤ 34.502 × 103
The value obtained from the above equation show that that the maximum moment due
to thermal expansion will produce no disturbance, if an expansion loop is used for 200
ft length of pipe.
68
As it is already mention that a straight main pipe section has been selected for
analysis, which is divided into the following sections A-B, B-C, C-D, D-E, and E-F.
As this pipe section is considered as straight beam with one anchor support and four
vertical restraints, so there are five unknowns in this problem. For this purpose to
solve this problem singularity method has been followed.
69
For segment A-B as shown in Figure 7-4 below, taking the weight, shear force and
moment equation and then solving for length L1 = 22.22 ft.
w( x) = − M 0 〈 x〉 −2 + R0 〈 x〉 −1 − w〈 x〉 0 − R1 〈 x − a〉 −1 − M 1 〈 x − L〉 −2
V ( x) = − M 0 〈 x〉 −1 + R0 〈 x〉 0 − w〈 x〉1 − R1 〈 x − a〉 0 − M 1 〈 x − L〉 −1 (7.8)
M ( x) = − M 0 〈 x〉 0 + R0 〈 x〉1 − w〈 x〉 2 − R1 〈 x − a〉1 − M 1 〈 x − L〉 0
Integrating the moment equation twice and putting boundary conditions we get
M 0 〈 x〉 2 R0 〈 x〉 3 w〈 x〉 4
EIy ( x) = − + − =0 (7.9)
2 6 24
As for segment AB, x = L1 = 266.64 in
R0 + R1 + R2 + R3 + R4 = wL + 800 (7.15)
R4 = 1591 lb
Plotting shear force and bending moment diagram for the beam solved above
200
0
0 267 507 747 987 1118 -200
-400
-600
-800
Pipe Length
10000
Bending Moment
0
0 267 507 747 987 1118
-10000
-20000
-30000
PDo 0.75i × M A
SL = + ≤ 1.0S h (7.16)
4t Z
These all inputs are arranged in Table 7-6 below, where the different parameters are,
P = Internal Pressure, psi
Do = Out Side diameter of Pipe, in
t = nominal wall thickness, in
Z = Section modulus of pipe, in3
MA = Resultant moment due to weight and other sustained loads, lb-in
From the results obtained both manually and on ANSYS, the difference in
maximum deflection is 6.4% where on the other hand the difference in the max.
Bending moment is 1.35%. Deformation is less than 0.1 inch and also the
maximum bending stress is 1947.55 psi which is quite less than the allowable
stress of the pipe.
WL2
S = 0.75 × i × 12 × ( × (1.5G ) (7.17)
8× Z
Where
For seismic lateral load based on static analysis is to be used to evaluate power piping.
It is performed by analyzing a piping system for the statically applied uniform load
75
V = Z × I × K × C × S ×W (7.18)
V = Seismic lateral load, lb
Z = constant depend upon earth quake zone 0.5 up to 1.0 = 1( Assuming
maximum)
K = Occupancy factor b/w 1.00 and 1.5 = 1 (Low occupancy region)
1
C= =0.12
15 T
T =Fundamental period of structure, s = 0.3 sec
S = soil factor b/w 1 and 1.5 = 1.5 (Data provided)
W = Total dead weight of the structure = 10,000lb (For 200 feet of pipe length)
To verify that the applied seismic loads are with in the limits as defined by the code,
following equation is used [1].
PDo 0.75i ( M A + M B )
+ ≤ KSh (7.19)
4t Z
Where
Using the values given in Table 7-8, below for obtaining the comparative results
of seismic load,
All the loads obtained from previous calculations are arranged in Table 8-1 below;
Table 8-1 Available loads for analysis of anchor support [From previous calculations]
Finding the reaction in the middle of the beam, maximum moment and section
modulus of this beam using the following equations [4].
R=wxL (8.1)
Where
w = 73 lb/in
L = 8 in
= 568.14 lb
Z = M/σallowable (8.3)
Using the value of M from Equation (8.2) and for allowable stress = 27 ksi
= 2.28/27
= 0.10 in3
Looking values from Appendix Table A9:
For Z=>0.1
Required section comes out to be C5 x 9
Section modulus = Zy = 0.45 in3
Zx = 3.5 in4
The other properties of this beam are arranged in Table 8-2 below;
First of all finding the reaction at the middle using Equation (8.2),
σ = M/Z ( 8.4)
= 2.342/0.45
= 5.204Kips
5.20 < 27 = σ all Now to find the maximum deflection, equation (8.5) is used [4].
Where
I = 0.632 in4
w = 73 lb/in
L = 8 in
E = 29 x 106psi
From Equation (8.5) the deflection comes out to be: y max = 0.00204 in
80
As the working stress and the deflection are well with in the limits so the beam used is
quite safe with working conditions.
Method Max. Deflection, in Max. B. Moment, in- Kips Max. Stress, kips
From table 8-3 above it is cleared that the difference in deformation b/w the two
methods is 8%, for bending moment the difference is 8.5% while in maximum
stress the difference is 2.8 %. Comparing these values to the allowable limits for
deflection and stress, the beam is found to be safe for the available loads.
= P + MH x m (8.6)
Where
P = Compressive load on column, lb
MH = Horizontal equivalent moment, lb-in
m = Design factor for column
Equivalent Horizontal Load ‘FH’= (wind load + earth quick load + Impact load -
thermal load)/3.5
= 3714 lb
MH = FH x leff
= 24.36 ft-kips
Taking value of m = 2 (Appendix Table A10)
Column effective Design load = 585.47 + 24360 x 2
= 49.29 kips
Starting trial iteration from NPS 3 in, 3.5 in up to 4 in
Selecting NPS = 4 in with design load of 82 kips
From column design using Appendix Table A-12 for circular standard pipe, and
taking the parameters are arranged in Table 8-4 below;
To check that column is safe under the applied loads critical load factor Equation
(8.7) is used, if this factor is less than 1.15, and then Equation (8.8) will be used for
load verification.
84
kl Fy
λc = × (8.7)
r E
Where
λc = critical load factor
(kl)/r = slenderness ratio
Fy = yield strength of the column material, ksi
E = modulus of elasticity, Mpsi
Using Table 8-4, and putting the values in above equation,
2 × 3.28 36 × 103
λc = ×
1.51 29 × 106
λc = 0.487 ≤ 1.15
If the critical load factor is less than 1.15, then Equation (8.8) can be used to calculate
the critical force [7].
( 2
Fcr = 0.658λc × Fy ) (8.8)
Fcr = 35.598kips
⎛ fa ⎞ ⎛ fb ⎞
⎜ ⎟ + ⎜ ⎟ 〈1.0 (8.10)
⎝ Fa ⎠ ⎝ Fb ⎠
For axial stress
fa = P/A (Using Table 8-4)
= 585.74/3.17
= 0.185 ksi
At slenderness ratio = kl/r = 52.3132, looking value of Fa from Appendix Table A11,
Fa = 26.39 ksi
fa/Fa = 0.00701
For Bending Stress
MC
fb = (8.11)
I
Where
M = Bending moment = 24.36 kips-in (From above calculations)
C = D/2 = 4.5/2 = 2.25 in
I = 7.32 in4 (From Table 8.4)
24.36 × 2.25
fb =
7.32
fb = 7.48ksi
Allowable bending stress by using equation below [7]:
Fb = 0.85 x Fy
Fb = 30.6 ksi
fb/Fb = 0.238
Putting these values in above equation
( 0.007 ) + ( 0.238) 〈1.0
0.2459〈1.0
The result shows that the selected column for the calculated loads is quite safe.
∑F y =0 (8.12)
86
Ry = Fy
(Compressive load from Table 8-1)
Ry = 585.74
For deflection of the column, considering it is a cantilever beam and solving it for the
equivalent effective load by using the following equation [4].
Fl 3
y= (8.13)
3EI
Where
F = equivalent horizontal force, lb
L = Length of the column, ft
I = Moment of inertia, in4
E = Modulus of Elasticity, Mpsi
These all values are arranged in Table 8-5 below;
P LC
σ max = + ( Feq ) (8.14)
A I
Where
P = Compressive axial load, lb
A = Cross sectional area of column, in2
L = Length of the column, ft
I = Moment of inertia, in4
F = equivalent horizontal force, lb
C = D/2 = 4.5/2 = 2.25 in
87
All the input data are arranged in Table 8-6 below for combined stress.
Equation (8.14), gives the maximum stress due combined axial and bending load.
Difference b/w both methods for deformation 4.9%, while for maximum stress, the
difference is 3.8%. The deformation value comes out to be slightly greater than
the normal value, this is because at the same time shock load of more than 12 kips,
high seismic load, high thermal load were present and also if the wind has speed of
100 mile/hour, then under such conditions above deflection value is possible.
M
Bearing − pressure = ± (8.15)
( BN 2
6 )
Where
fp
tp = 2×l × (8.16)
Fy
where
l = max (m, n), in
fp = Bearing pressure due to concentric load = 2.61 psi (Calculated above)
Fy = Yield strength of base plate, 36 ksi (Appendix Table A-10)
Distances from the column to edge of the plate are:
N − Do 15 − 4.5
m= = = 5.25in
2 2
B − Do 15 − 4.5
n= = = 5.25in
2 2
Therefore l = 5.25 in and putting all the values in the above Equation (8.16):
t p = 2 × 5.25 × 2.61
36000
t p = 0.09in
Now the pressure from the edge to the pipe edge is fp)m1= 522.3 – 182.8 = 339.5 Psi
M=σxZ (8.17)
Taking the section modulus and bearing pressure of the two sections, Equation (8.17)
becomes,
⎡ f p) fp ⎤
M = B × m 2 ⎢ m1 + ⎥
⎣ 6 3⎦
⎡ 339.5 522.3 ⎤
M = 15 × 5.252 ⎢ +
⎣ 6 3 ⎥⎦
M = 39.37in − kips
The thickness required to resist this moment [7]:
6× M
tp = (8.18)
B × σ all
where
M = 39.37in-kips
σall = 27 kips (using design factor of 0.85 from Appendix Table A-11)
Side of the base plate, B = 15 in
6 × 39.37
tp =
15 × 27
t p = 1.18in
Selecting the thickness to resist the bending moment b/c of its greater value, using
standard thickness for plate 1.25 in, base plate dimensions come out to be
1
15 × 15 × 1 in
4
The total force on base plate and then force per bolt;
M 24.36
F= = = 29.98kips
d 9.75
12
Force = 29.98 = 7.5kips
Bolt 4
Allowable stress for bolts = 21ksi
Nominal area of bolt = 7.5/21 = 0.357 in2
D = 4 × 0.357
Diameter of bolt π = 0.68 in
D ≈ 0.75 in
And Bolt length by using bearing stress equation [7].
F
L= bolt (8.19)
D ×π ×σ
using value of force and diameter of bolts as calculated
93
7.5 × 103
L= bolt
0.75 × π × 160
L = 19.89in
Bolt length = 20 in
Bolt length comes out to be 19.89 in which rounded up to 20 inch. The bolt length for
such base plate and column is quite reasonable. The calculated load in tension from
the load conditions 7.5 kips for each bolt which is less than the allowable tension by
factor of 3.7 as bolt minimum allowable tension is 28 kips.
Parameter Value/Size
1
Base plate size 15 × 15 × 1 in
4
9200
9000
Von Mises Stresses
8800
8600
8400
8200
8000
7800
0 10000 20000 30000 40000
Num ber of Elem ents
Figure 9-2 Convergence line b/w no. of elements and Von Mises Stresses (psi)
96
10 Conclusions
Following conclusions are made from the analysis of the designed system.
1) The designed pipe verified all the conditions defined by the ASME Boiler and
Pressure Vessel code B31.1. Thickness and working pressure calculated are in
the safe limit. Thermal, Seismic and Sustained analysis results obtained are in
the safe limits defined by the Code.
3) The analysis shows that the complete system is safe and the results are verified
by manual calculations and ANSYS software.
4) On the positive side of the manual calculations lays the fact that it gives fully
basic concept of the piping system. While the assumptions made during
manual calculations make the results slightly differ from the software results.
5) As for thermal analysis is concerned, guided cantilever method was used and
this proved to be a useful tool for thermal stress loads calculations.
11 Future Recommendations
After completing the design of main header pipe and anchor support of the steam
piping system, following suggestions are recommended.
1) For future work more stress should be given on the proper use of the piping
software so that complex piping networks can be analyzed with it.
4) To complete the analysis of Anchor support, analysis of base plate and bolts
are also suggested.
101
References
[1]. Mohinder L. Nayyar, Piping Hand Book, 7th Edition, McGraw-Hill, Inc.
Singapore, 2000.
[2]. Sam Kannappan, Introduction To Pipe Stress Analysis, John Wiley & Sons,
USA, 1986.
[3]. Paul R. Smith, P.E, Piping and Piping Supports Systems, McGraw-Hill Book
Co., 1979.
[4]. J.E Shigley and C.R. Mischke,Mechanical engineering Design,5th edition,
McGraw-Hill Book Co. ,1989.
[5]. The American Society of Mechanical engineers, ASME B31.1-2001Power
piping, Revised edition 1998 ASME, USA.
[6]. Spirax Sarco Company Ltd, “Supports and Expansion Loops”, International
Site for Spirax Sarco.2008.
URL: http://www.spiraxsarco.com/resources/steam-engineering-tutorials/
[7]. The American Institute of Steel Construction, load & Resistance factor
Design, 2nd edition, USA, 1994.
[8]. L. Daugherty, B. Franzini, John Finnemore, Fluid Mechanics, Si Metric
edition.
[9]. Arthur H. Nilson, Design of Concrete Structures, 12th edition,Mc Graw Hill,
Inc., Singapore, 1982.
[10]. TPC Training System, Piping System, A Dun & Brad Street Comp, 1974.
[11]. David R. Sherwood, The Piping Guide, 2nd Edition, Syentek books.Inc., 1991.
[12]. A. Keith Escoe, Pipe Line Assessment Guide, Elseveir Book Aid Int. 2006.
102
APPENDIXE
103
Table A-1 Allowable stresses and yield stress for seamless Piping, KSI [2].
104
Table A-5 Value of casting quality factor used in pipe thickness calculations[2]
Table A-7 Table Stress reduction factor used in allowable stresses [5]
Table A-13 Stress Intensification factor and flexibility factors for various sections of pipe [5]
112
Figure A-1 Drag co-efficient v/s Reynolds no. used in wind loadings [1]
113
Vita
Muhammad Sardar was born on April 02, 1982 in a small village Kotigram of
Distt. Dir. He did his matriculation from Government High School Kotigram
Distt. Dir (lower). After matriculation, he got admission in Islamia College
Peshawar and passed his F.Sc (Pre-Engineering) in 2001 and did B.Sc.
Mechanical Engineering from N-W.F.P. UET Peshawar in 2006. After serving
Ghandhara Industires Limited (ISUZU), Karachi for six months, he joined
Pakistan Institute of Engineering and Applied Sciences, Islamabad as MS
Mechanical Engineering fellow on 13th of November, 2006.