STRESS ANALYSIS

STRESS ANALYSIS –
PURPOSE
To Ensure
• Safety of Piping and Piping Components
• Safety of Connected Equipment and
Supporting Structure
• Piping Deflections are within the limits.
 STRESS ANALYSIS –
INPUT REQUIRED
In order to determine the effects of
Expansion/Contraction and Stresses within
a Piping system, it is necessary to know
• Which code applies to the system
• Service conditions
• Material Specification
• The pipe size and wall thickness of each of
the piping components
 STRESS ANALYSIS –
INPUT REQUIRED
• The layout of the system including
dimensions and the thermal movements, if
any, of the terminal points
• Limitations of end reactions on terminal
points as established by equipment
manufacturer
 STRESS ANALYSIS –
INPUT REQUIRED
PID – LINE NUMBER, MATERIAL
PROCESS CLASS, EQUIPMENTS
SLUG/ SURGE DATAS
LINE LIST – DESIGN AND OPERATING
PRESSURE & TEMPERATURE, FLUID
DENSITY, INSULATION THICKNESS,
INSULATION DENSITY
PIPING MATERIAL SPECIFICATION – CORROSION
ALLOWANCE, PIPING MATERIAL, PIPE
WALL THICKNESS, PIPING COMPONENT
DETAILS
PIPING LAYOUT/ ISOMETRIC DRAWING –
PIPE SIZE, PIPING ARRANGEMENT
 STRESS ANALYSIS –
INPUT REQUIRED
EQUIPMENT GENERAL ARRANGEMENT
EQUIPMENT DRAWING – EQUIPMENT NOZZLE DETAILS,
NOZZLE DISPLACEMENTS, ALLOWABLE
NOZZLE LOADS
CIVIL & CIVIL & STRUCTURAL ARRANGEMENT
STRUCTURAL DRAWING, STRUCTURAL STIFFNESS,
STRUCTURAL DESIGN BASIS

CONTROL & THRUST LOAD – SAFETY/ RELIEF VALVE,

INSTRUMENTATION RUPTURE DISC

ENVIRONMENTAL DATAS – AMBIENT &

MAX/ MIN TEMPERATURE, WIND DATA,
GENERAL EARTHQUAKE DATA, WAVE LOADS, SNOW
& ICE LOADS, SOIL DATA
CLIENT REQUIREMENTS, IF ANY
 STRESS ANALYSIS –
CLASSIFICATION OF LOADS
 PRIMARY LOADS

• SUSTAINED LOADS
Those loads that do not vary considerably over
time and are constantly acting on the system.
Example:
1) Pressure, Internal & External
2) Weight of the system, includes both that of the
piping material and the operating fluid.
 STRESS ANALYSIS –
CLASSIFICATION OF LOADS
• OCCASIONAL LOADS
Those loads that act on the system on an
intermittent basis.
Example:
1) Wind Load
2) Seismic Load
3) Snow and Ice Load
4) Hydraulic Load – Pressure surges such as
those caused by pump starts and stops, valve
actuation, water hammer, and by the energy
discharged by a pressure relief valve.
5) Wave Load
 STRESS ANALYSIS –
CLASSIFICATION OF LOADS

EXPANSION LOADS
Loads due to Piping displacements resulting
from thermal expansion, piping support and
terminal movements
 STRESS ANALYSIS –
STRESS CATEGORIES

• PRIMARY STRESSES
Due to Primary Loads – Weight of Piping
and its Components, External Forces and
Moments etc.,
• SECONDARY STRESSES
Due to constraint of displacements –
Thermal expansion/ contraction and
Support and Terminal movements
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS
• CODE REQUIREMENT
EXAMPLE:
ASME B31.3 requires the analysis of four stress
limits:
1. Stresses due to sustained loads.
SL < S h
where:
SL = longitudinal stress, MPa (psi)
Sh = basic allowable stress at maximum material
temperature, MPa (psi), from code (ASME B31.3
Appendix A).
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS
2. Stresses due to Displacement Strains
SE < SA
where:
SE = displacement stress range, MPa (psi)
SA = allowable displacement stress range, MPa (psi)
=f [1.25 SC + 0.25Sh + (Sh - SL)]
f =Stress reduction factor
SC = basic allowable stress at minimum material
temperature, MPa (psi), from code (ASME B31.3
Appendix A).
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS

3. Stresses due to Occasional Loads

SL < 1.33 Sh
where:
SL = longitudinal stress, MPa (psi)
Sh = basic allowable stress at maximum material
temperature, MPa (psi), from code (ASME B31.3
Appendix A).
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS

4. Stresses due to Hydro test loads

SLT < 0.9SY
where:
SLT = longitudinal stress, MPa (psi)
SY = Yield Strength, MPa (psi), from code (ASME
B31.3 Appendix A).
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS
• PIPE DEFLECTION

 Vertical Pipe deflection in Sustained cases shall be limited to 6 mm

 Horizontal pipe movement under occasional loads (wind,
accelerations, surge, slugs,…) shall be limited to 20 mm maximum
(the target being 5 mm)

 For Pipes connected to Pumps and Compressors, during flange mating

case,
the gap between the face of flange of the line and equipment
< 2mm along the pipe axis direction and
< 1mm in the other direction
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS
• TERMINAL REACTIONS

1) PUMPS
Allowable Loads and Moments acting on Suction and Discharge
pump nozzles shall be 2 times API 610 Table 4 (4 times values of
API 610 Table 4 when checked according to Appendix F).

2) AIR COOLED EXCHANGERS

Allowable loads and moments acting on air cooled exchanger header
nozzles shall be 2 times those specified in API 661.
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS

3) VESSELS AND SHELL AND TUBE HEAT

EXCHANGERS
The allowable piping loads and moments acting on nozzles of
process vessels (i.e, columns, drums,…) and on shell and tube
heat exchangers are as in table 1.

4) WELDED STORAGE TANKS

Evaluation of actual forces and moments shall be carried out to
API 650 Appendix P
 STRESS ANALYSIS –
CRITERIAS FOR ANALYSIS

• FLANGE LEAKAGE CALCULATION

 For flanges diameters above 10" and ratings above 600#, the most
loaded flange will be checked against risk of leakage.

 Equivalent pressure method from A.S.M.E III Div 1 NB 3647.1 will

be used.

 External bending moments and axial force will be converted into an

equivalent pressure Pe. This equivalent pressure Pe will be then
added to the internal design pressure Pd to obtain the total pressure
Pt. The total pressure Pt will be compared and kept below the
hydrotest pressure Ph.
 STRESS ANALYSIS –
PIPING FLEXIBILITY

T1 T2

2000 mm

Thermal Expansion rate = 5 mm/ m

Expansion = 2000/1000 x 5 = 10 mm
 STRESS ANALYSIS –
PIPING FLEXIBILITY
1

T1 T2

T1 T2
 STRESS ANALYSIS –
PIPING FLEXIBILITY
MINIMUM LEG LENGTH

T1

T2
 STRESS ANALYSIS –
PIPING FLEXIBILITY
EXPANSION LOOP

T1 T2
 STRESS ANALYSIS –
PIPING FLEXIBILITY
EXPANSION BELLOW

T1 T2
 STRESS ANALYSIS –
PIPING FLEXIBILITY
TYPES OF SUPPORTS

• RIGID SUPPORT
– REST
– GUIDE
– STOP
– ANCHOR
– FIXED POINT

• HANGERS
– VARIABLE SPRING HANGER
– CONSTANT SUPPORT HANGER
 STRESS ANALYSIS –
CALCULATION LEVEL
CALCULATION LEVELS

Design temperature (°C) LEVEL1

LEVEL 2

250 LEVEL 3

200

LEVEL 3
150

100

LEVEL 2
50 LEVEL 1 LEVEL 3
LEVEL2
0 Line Size (inches)
1 2 3 4 6 8 10 12 14 16 18 20 22 24 26 28 30
LEVEL 1
-30 LEVEL 2
-50

LEVEL 3
LEVEL2
 STRESS ANALYSIS –
CALCULATION LEVEL
• LEVEL 3
– process pipes DN 80 and larger if connected to rotating equipment ;
– pipes connected to air-cooled heat exchangers ;
– pipes connected to pulsating equipment ;
– pipes to and from boilers and heaters ;
– in cases where differential settlement of equipment and/or supports is expected ;
– process regeneration pipes ;
– pipes where engineered items are required like spring supports, expansion joints,
snubbers etc. ;
– pipes subject to slug flow or water hammer ;
– if required by local regulations ;
– pipes for two-phase flow ;
– flare pipes DN 100 and larger ;
– pipes subjected to relief loads ;
– pipes DN 80 and larger in very toxic service operating at temperatures above
200 °C.
 STRESS ANALYSIS –
METHOD OF ANALYSIS
• Level 1
Approximate, visual inspection method

• Level 2
Simplified analysis, charts, cantilever method

• Level 3
Comprehensive method by using Stress Analysis Software –
CAESAR II, CAE PIPE, AUTO PIPE
 STRESS ANALYSIS –
CRITICAL LINE LIST
• CALCULATION NUMBER

• LINE NUMBER

• DESCRIPTION

• DESIGN PRESSURE AND TEMPERATURE

• STRESS LEVEL
 STRESS ANALYSIS –
OUTPUT
LOCATION AND TYPE OF SUPPORTS,
SPECIAL REQUIRMENT OF SUPPORTS –
GAP, PTFE PAD REQUIREMENT,
ADJUSTABLE SUPPORT
PIPING
SUPPORT LOADS
SPECIAL TEE/ REDUCER REQUIREMENT
HIGHER FLANGE RATING REQUIREMENT

STRUCTURES PIPING LOADS ON STRUCTURES

EQUIPMENT NOZZLE LOADS

THANK YOU