Stress Analysis Of Hot Wall Flue Gas Piping At FCCU Plant, Reliance 27

Chapter 7 : MANUAL CALCULATIONS

Before we move on to the CAESAR results lets check the feasibility of the
software.
7.1 Considering a Cantilever pipe and calculating stresses due to self
weight and weight of water and comparing with CAESAR Output

Given :-

Leg 10-20 Length, L = 3500 mm

O.D. of pipe, Do = 275.05 mm
Thickness of pipe, t = 9.271 mm
Corrosion allowance, C.A = 1.6 mm
Design Temperature T1 = 350 ºC

Material :- A 106 Gr. B

Density of Pipe = 7833.1567 kg/m³.

According to ASME B31.3[8],

Allowable cold stress range at 21 º C = Sc = 137.9 N/mm²
Allowable hot stress range at 350 º C = Sh = 116.4 N/mm²

7.1.1 Solution :-
SA = Allowable stress range = f ( 1.25 Sc + 0.25 Sh )
= 1.0 ( 1.25 * 137.9 + 0.25 * 116.4 )
…..( where f = 1.0 for 7000 load cycles )
SA = 201.5 N/mm² …(7.1)

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 Stress Analysis Of Hot Wall Flue Gas Piping At FCCU Plant, Reliance 28

W1 = Weight of the pipe

= Density of Pipe material * Volume of pipe * 9.81
= 7833.1567 * { ( pi/4) * (Do² - Di²) } * L * 9.81
= 7833.1567 * { ( pi/4) * (0.27305 ² - 0.25451 ²) } * 3.5 * 9.81
W1= 2066 N …(7.2)

W2 = Weight of water
= Density of water * Volume of water in pipe * 9.81
= 1000 * { ( pi/4) * ( Di²) } * L * 9.81
= 1000 * { ( pi/4) * ( 0.25451 ²) } * 3.5 * 9.81
W2= 1746.8 N …(7.3)

Therefore,
Total weight, W = Weight of pipe (W1) + Weight of water (W2)
= 2066 + 1746.8
W = 3812.8 N …(7.4)

Therefore,
Shear force, Fs = 3812.8 N

Thus, Bending Moment, Mb = Fs * X c.g

= 3812.8 * ( 3.5 / 2 )
Mb = 6672.4 N-m …(7.5)

Considering, t = t actual - Corrosion allowance

= 9.271 – 1.6
t = 7.671 mm

Therefore, Di = Do – 2 * t
= 273.05 – 2 * 7.671
Di = 257.71 mm

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 Stress Analysis Of Hot Wall Flue Gas Piping At FCCU Plant, Reliance 29

Now calculating stresses and comparing with CAESAR OUTPUT. Detailed

CAESAR results are given in APPENDIX D.

1) Longitudinal stress or axial stress = ( P Di) / ( 4 * t )

= ( 0.4 * 257.71 ) / ( 4 * 7.671 )
Longitudinal stress or axial stress = 3.35 N/mm² …(7.6)
where as CAESAR output gives axial stress = 3.26 N/mm²

2) Bending stress = Mb / Z
Now,
Section Modulus, Z = {pi* (Do4- Di4)} / (32*Do)
= {pi* (0.273054- 0.2757714)} / (32*0.27305)
= 0.000412677 m³
Z = 412677 mm³ …(7.7)
Therefore from eqn.(7.5) & (7.7),
Bending Stress = (6672.4 * 10³ / 412677 )
Bending Stress = 16.16 N/mm² …(7.8)
where as CAESAR output gives Bending stress = 16.16 N/mm²

3) Hoop stress = ( P Di) / ( 2 * t )

= ( 0.4 * 257.71 ) / ( 2 * 7.671 )
Hoop stress = 6.72 N/mm² …(7.9)
where as CAESAR output gives Hoop stress = 6.72 N/mm²

4) Max 3D stress intensity

= Axial stress + {(Bending stress)² + 4(Torsional stress)² }^0.5

In this case Torsional stress = 0, as there is no Torsional moment acting on the

pipe.
Therefore from eqn.(6) & (7),
Max 3D stress intensity = 3.35 + {(16.16)² + 4(0)² }^0.5
Max 3D stress intensity = 19.51 N/mm² …(7.10)
where as CAESAR output gives Max 3D stress intensity = 19.42 N/mm²

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 Stress Analysis Of Hot Wall Flue Gas Piping At FCCU Plant, Reliance 30

Now Calculating Deflection of Pipe at node 20,

We have for Cantilever beam[10],
y = ( w * L4 ) / ( 8 * E * I )
From ASME B 31.3[8],
Modulus of Elasticity, E = 203391 N/mm² at 350 ºC …(7.11)

Moment of inertia, I = { pi* (Do4- Di4)} / 64

= { pi* (273.05 4- 254.51 4)} / 64
I = 66899732.1 mm4 …(7.12)

Weight per meter, w = W / L

= 3812.8 / 3500 = 1.08937 N/mm …(7.13)

Therefore from eqn. (7.11), (7.12) and (7.13),

y = ( 1.08937 * 3500 4 ) / ( 8 * 203391 * 66899732.1 )
y = 1.502 mm ( downward direction ) …(7.14)

where as CAESAR output gives deflection, y = - 1.523 mm i.e. in downward direction.

Thus it is seen that the result obtained by CAESAR and manual calculation
are nearly same.

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Stress Analysis Of Hot Wall Flue Gas Piping At FCCU Plant, Reliance 31

7.1.2 CAESAR OUTPUT

Figure 7-1

Figure 7-2

Figure 7-3

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 Stress Analysis Of Hot Wall Flue Gas Piping At FCCU Plant, Reliance 32

7.2 Considering a Cantilever pipe having perpendicular supporting pipe

and calculating expansion stress due to temperature and comparing
with CAESAR Output

Given :-
Leg 10-30 Length, L = 7500 mm
O.D. of pipe, Do = 275.05 mm
Thickness of pipe, t = 9.271 mm
Corrosion allowance, C.A = 1.6 mm
Design Temperature T1 = 350 ºC

Material :- A 106 Gr. B

Density of Pipe = 7833.1567 kg/m³.
According to ASME B31.3,
Allowable cold stress range at 21 º C = Sc = 137.9 N/mm²
Allowable hot stress range at 350 º C = Sh = 116.4 N/mm²

7.2.1 Solution :-
SA = Allowable stress range = f ( 1.25 Sc + 0.25 Sh )
= 1.0 ( 1.25 * 137.9 + 0.25 * 116.4 )
…..( where f = 1.0 for 7000 load cycles )
SA = 201.5 N/mm² …(7.15)

Calculation of expansion of leg 10-20,

L1 = 3.5 m
T1 = 350 ºC
T2 = 21 ºC = ambient temperature

Expansion ¨ 10-20 is calculated by formula[8],

¨ = Į . ¨T . L
where,
Į = Thermal Expansion coefficient m/m º C
¨T = Temperature difference = ( 350-21 ) = 329 º C

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 Stress Analysis Of Hot Wall Flue Gas Piping At FCCU Plant, Reliance 33

L = Leg length of 10-20 i.e. 3.5 m

From ASME B31.3[8],

Į = 13.194 * 10-6 m/m º C at 343.333 º C
Į = 13.284 * 10-6 m/m º C at 357.222 º C
Using interpolation method we get,
( Į - 13.194 * 10-6 ) = ( 13.284 – 13.194 ) * 10-6
( 350 – 343.333 ) ( 357.222 – 343.333 )

Solving the above eqn. we get,

Į =1.3237 * 10-5 m/m ºC at 350 °C …(7.16)

Now expansion of leg 10-20,

ǻ10-20 = Į . ¨T . L
= 1.3237 * 10-5 * 329 * 3.5 * 1000
ǻ10-20 = 15.242 mm …(7.17)
As node 10 is anchored, the expansion takes place near node 20 and as leg 10-20
is horizontal and parallel to X axis, the deflection is in X axis.
CAESAR output gives deflection, DX = 15.241 mm i.e. in positive X direction.

Similarly expansion of leg 20-30,

ǻ20-30 = Į . ¨T . L
= 1.3237 * 10-5 * 329 * 4.0 * 1000
ǻ20-30 = 17.42 mm …(7.18)
As node 30 is supported from below, the expansion takes place near node 20 and
as leg 20-30 is vertical and parallel to Y axis, the deflection is in + Y axis.

CAESAR output gives deflection, DY = 17. 376 mm i.e. in positive Y direction.

K.L.E. Society’s College Of Engineering and Technology, Belgaum