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A rigid piping system experiences stresses during operation at high temperatures.
Providing sufficient flexibility in routing is critical to ensure stresses in the piping system
is within acceptable limits.
Be focused on providing flexible routing for large bore and temperature critical piping.
Flexibility in piping connected to strain sensitive equipments like pumps, compressors,
columns, turbines, plate heat exchangers, etc. is a must.
What it means!!!
The piping designer should be aware of the stress and support concepts in piping layout
which are the guiding principles behind flexible pipe routing.
The piping designer should be aware of what pipe expansion means, how rigid piping
induces stress and how to provide minimum expansion length using guided cantilever
tables.
Stress engineer is always there to review flexibility but piping designer uses best
judgment and coordinates with stress engineer as needed to design a flexible and
stable pipe route upfront.
Understanding stress and flexibility concepts will help designer in reducing cycle time
for the preparation of an effective layout which is acceptable to the stress engineer.
Increases the technical expertise of the designer in piping layout and design and also
gives a good understanding of pipe supporting norms.
Will lead to better design, more effective and accurate material take-off & shorter
schedule.
Pump suction and discharge piping (High temp and sizes ≥ 12” more critical)
Furnace and Reactor piping
Column and Air Cooler piping
Column and Reboiler piping – Two phase flow
Compressor piping
Turbine piping
Provide sufficient pipe leg perpendicular to pump suction axis so as to absorb suction
line growth. Refer Figure 1.
Case 1 piping is more flexible as column nozzle is perpendicular to pump axis and
pumps set equidistant from column centerline helps minimize differential thermal growth
across pump axis.
Fig. 1: Typical pump routings
Case 2 has column nozzle parallel to pump axis and this layout is less flexible because
thermal growth along pump axis has to be absorbed by offset loop.
Cases 3 are preferred arrangement for higher temps and higher suction/discharge pipe
sizes.
Provide min 5D straight run from first elbow to pump suction.
First base support shall be adjustable.
Consider low friction slide plate where required.
(Case 1) Common practice is to locate both Furnace & Reactor on same side of pipe
rack so that connected line on rack moves away from the equipments during thermal
expansion
(Case 2) In alternate layout mid section of line on rack acts as pivot allowing pipe on
either side to move away from equipment due to thermal expansion (more loads on
nozzles).
Fig. 2: Typical Furnace reactor Layout
Tall Column Piping (Fig. 3)
Considering column expansion is very critical to effective and efficient piping design.
Column skirt expansion is also critical.
Use the tables for standard pipe guide spacing for supporting of vertical lines.
Avoid loop on vertical down comer alongside the column.
First support is almost always a “Rest Support”.
Fig. 3: Typical column piping
Conclusions:
Reduce stress by providing flexibility in the piping system and proper balanced
supporting to ensure uniform distribution of piping loads.
Remember that pipe moves when hot and movement shall not be restrained by
adjacent pipe.
Understand that different materials have different thermal coefficient of linear expansion
(i.e. SS expands more than CS).
Most sustained case loads (dead loads) in a piping system can be addressed by the
designer by use of support span table and guide tables.
Avoid fitting-to fitting routing of lines especially for higher sizes and temps
Remember that expansion leg in the other direction/plane is good but in third
direction/plane is better (3-D loop better than 2-D)
Piping design owns the ultimate responsibility for effective, economic and efficient
design
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Each final report starts with a very nice front page. The front page normally includes the
project name; project no, client name with logo, PMC name with logo and the
performing organization or EPC consultant name with logo. It should also include the
name of the stress system and system number for which report is prepared.
In the 2nd page normally it is better to include a table with revision details, name of
performer, checker and approver along with signature and report issue date. It informs
the client about responsible persons who are performing the analysis.
Next sheet or page should include a brief content of all the major points with page
numbers which are included in the report. From this page the client will be able to know
whether all relevant points are incorporated and considered in the analysis or not.
From next page onwards, the actual analysis report of each stress system starts.
Broadly the report should include the following major points:
Briefly the abovementioned points are sufficient for a complete report. However if client insist for
any additional details you have to include the same along with the above mentioned points.
Hope now you will be able to prepare a complete report of the stress systems what you are
performing.
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II
2. Static Method of Seismic Analysis of Piping System using Caesar II
3. BASICS OF PIPE STRESS ANALYSIS: A PRESENTATION-Part 1 of 2
4. Enriched features of Caesar II-2016 (Version 8.0)
5. Static Method of Wind Analysis of Piping systems in Caesar II using Pressure Vs
elevation Method
6. Piping Stress Engineer required for Philadelphia (Experience: 5 yrs+)
7. ASME B 31J & B 31J Essentials: Why these are useful in Piping Stress Analysis?
Static Method of Wind Analysis of Piping systems in
Caesar II using Pressure Vs elevation Method
Wind analysis is performed based on Client/ITB requirement. Wind load is an occasional load
which normally occurs less than 20% of plant operating time. There are two methods for wind
analysis-Static and Dynamic. In this article I will try to explain the static method of wind analysis
using Caesar II of COADE Inc following Pressure Vs Elevation Profile.
Criteria for selection of lines for Wind Analysis:
Criteria should be mentioned in ITB document. As a guideline the following can be followed
after verification from client:
Lines with outside diameter 10” and larger (including insulation) running on 10 m and
above.
Steam / Flare header on the pipe rack.
Other lines considered important as per stress engineer’s decision.
However if lines are covered by some shelter or other structures then wind analysis can be
ignored for those lines.
Data Required for Wind Analysis:
For wind analysis you must have following data from the client.
Wind shape factor: Normally for pipe elements the data varies from 0.6-0.8. Check in
ITB what value it says to use.
Pressure Vs Elevation Profile: Sometimes client provides this profile directly and
sometimes provides equation and data to calculate the profile. A typical wind profile will
be shown in diagram while explaining the steps required while analyzing using Caesar
II.
Elevation of the line under analysis. If HPP elevation is other than 0 you have to reduce
HPP from line global elevation to get actual elevation.
What to check:
As per code B 31.3 we have to check code compliance of the calculated stress (Sustained
+Wind). The allowable stress for wind analysis is 1.33 times Sh values. However sometimes
client requires to check the nozzle loading in Operating+ Wind cases (W+T+P+Win) for static
equipment. Normally client does not require wind load checking for rotating equipment.
Most of the steps are mentioned in attached images. All are self explanatory. However if you
face any problem in understanding please reply in comments section.
Model the piping system under analysis from piping isometric drawings.
Enter elevation of the first node in global coordinates.
Click on Wind/Wave check box on Caesar II Spreadsheet and mention wind shape
factor as shown in Fig. 1
Fig.1: Caesar Spreadsheet for Wind Analysis
Now run the analysis and go to the load case editor and select Pressure Vs Elevation
as shown in Fig. 2
In next step enter the pressure vs elevation profile in consistent unit and enter wind
direction cosines as shown in Fig. 3. Normally wind analysis is performed considering
wind flow from North, South, East and West direction. Accordingly Enter +1 or -1 in X or
Z direction. Wind analysis is generally not considered in vertical direction.
Fig. 3: Load Case Editor showing input of pressure vs elevation profile
Refer Fig. 4 and prepare the highlighted load cases additionally for wind analysis. Load
cases for L17 to L20 are for code compliance checking and load cases from L5 to L8 for
support and Nozzle load checking.
Refer Fig 5 and make the combination method as scalar or absolute for the shown load
cases.
Fig. 5: Load case Editor showing load case combination method.
In the final stage run the analysis and check results. If failing make suitable adjustments
to qualify the same.
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