STRESS ANALYSIS OF PIPING SYSTEMS

A COURSE
ON
STRESS ANALYSIS OF PIPING SYSTEMS
BY
S.VISWANATHAN
PURPOSE
The purpose of stress analysis is to ensure safe operation of piping systems for different
loading conditions both external and internal, expected to occur during the lifetime of the system in the
plant.
OBJECTIVES
1. Ensure that the stresses in the piping components in the system are within the allowable limits.
Thus, limiting the stresses as per relevant codes.
2. Limiting deflections (sag) within the allowable.
3. Limiting the nozzle loads on connected equipment.
4. Limiting the pipe displacements in order to avoid fouling with nearby pipe or equipment or
structures.
5. Evaluation of supporting requirements and their loads.
6. To find out unintentional disengagement of pipe from support.
DEFINITION OF STRESS
The internal resistance which the body offers to meet the load
Stress = Force or Load (N)/ Resisting Area (mm 2)
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STRESSES IN PIPING SYSTEM
1. Longitudinal Stress
Longitudinal or Axial stress is the normal stress acting parallel to the longitudinal axis of the
pipe.
If,
Internal Pressure (Design) = P
Outside Diameter = Do
Inside Diameter = Di
Wall Thickness =t
Then,
Longitudinal stress = P * 3.14 * Di2 / 4
-------------------------------------
3.14 * (Do2 – Di2) / 4
= P * Di2
------------------------------ Eqn. (1)
(Do – Di )
2 2
Longitudinal stress = P * 3.14 * Di2 / 4

-------------------------------------
3.14 * Di * t
= P * Di
------------------------------------- Eqn. (2)
4*t
Eqn (1) will give the accurate value where as Eqn (2) is approximate.
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2. Circumferential Stress (Hoop Stress)
Circumferential stress = P * Di * L
--------------------------
2*t*L
= P * Di
--------------------------
2*t
Circumferential (Hoop) stress is used to calculate the pipe minimum wall thickness required.
3. Bending stress
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Bending equation:
M Sb E
------ = ------ = -------
I C R
Where,
M = Bending moment in N-m
I = Moment of inertia of cross section in m 4
= 3.14
-------- x (Do4 – Di4)
64
Sb = Bending stress in N/m2
C = Distance of point of interest from neutral axis in m
E = Young’s modulus in N/m 2
R = Outer Radius of pipe in m
From bending equation,
Bending stress (Sb) = MxC

-------------
I
= M
-------------
I/C
Bending stress is maximum at the outer radius of pipe. i.e. when C = R
Maximum bending stress (Sbmax) = M

--------------
I/R
The term I / R is called Section modulus (Z).
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So,
M
Maximum bending stress (Sbmax) = --------------
Z
3.14
-------- x (Do4 – Di4)
64
Section modulus (Z) = ------------------------------------
Do / 2
3.14 (Do4 – Di4)

= -------- x ------------------
32 Do
Stress Intensification Factor (SIF)
Maximum Stress Intensity

SIF = -------------------------------------------
Normal Stress
During stress analysis, all the components in a piping system is considered as PIPE only with
SIF. For a straight pipe SIF = 1.0. For all other components, SIF is more than 1.0
It is used as safe factor to account for the effect of localised stress on piping under respective
loading.
In piping it is applied to fittings, branch connections etc where stress concentration and
possible fatigue failure may occur.
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STRESS – STRAIN RELATIONSHIP
Strain is the change in length of pipe to original length of pipe.
From the above curve, it can be seen that stress is directly proportional to the strain up to the point A.
The point 'A' is called the elastic limit and AO is called the elastic range. The Hooke's law that is the
ratio of stress to strain is constant valid up to A.
The material beyond A and up to C is partly elastic and partly plastic in behavior. The point B when
the wire yields to the applied stress and begins to flow, is called the yield point
Beyond A, if the stress is removed, graph between stress and strain does not follow AO. For example,
if the stress removed at C, graph follows CO’ and when stress is zero, strain is not zero or a
permanent deformation sets in the material. Therefore, OO | represents the permanent set.
Ultimate stress is the maximum stress that can be seen in a stress strain curve.
ALLOWABLE STRESS
The basic material allowable stress at operating / design temperature for a material is given as
minimum of
As per ASME B31.1
a) 1/4th of the ultimate tensile strength of the material at operating temperature

b) 1/4th of the ultimate tensile strength of the material at room temperature
c) 5/8th of the yield strength of the material at operating temperature (90% of yield strength for
austenitic stainless steels)
d) 5/8th of the yield strength of the material at room temperature (90% of yield strength for
e) 100% average stress for 0.01% creep rate per 1000 hours
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As per ASME B31.3
a) 1/3rd of the ultimate tensile strength of the material at operating temperature

b) 1/3rd of the ultimate tensile strength of the material at room temperature
c) 2/3rd of the yield strength of the material at operating temperature (90% of yield strength for
d) 2/3rd of the yield strength of the material at room temperature (90% of yield strength for
e) 100% of average stress for 0.01% creep rate per 1000 hours
f) 67% of average stress for rupture after 1,00,000 hours
g) 80% of minimum stress for rupture after 1,00,000 hours
Creep
It is the time dependant deformation of a material that occurs under load at elevated
temperatures.
Rupture
Larger size of crack is called rupture. During failure, first the crack is initiated in a pipe then
crack size will become critical and then there will be unstable rupture.
ALLOWABLE FOR NOZZLE LOADS / TERMINAL POINTS
Allowable forces and moments at equipment nozzles / terminal points can be obtained from the
manufacturer of particular equipment. In the absence of manufacturer allowable, following codes can
be referred to get allowable loads.
Centrifugal pumps – API 610 / ISO 5199
Positive displacement pumps – API 676
Centrifugal compressors – API 617
Reciprocating compressors – API 618
Steam turbines – NEMA SM23
Air cooled heat exchanger – API 661 / ISO 13706
Shell and tube heat exchanger – Manufacturer specification
Fired heaters - Manufacturer specification
Flat bottom welded storage tanks – API 650
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If allowable loads are provided by manufacturer and also not available in above codes, following
assumption can be made.
Allowable force Fa = 100 * D
Allowable moment Ma = 200 * D
Fa = Force in lbs
Ma = Moment in ft.lbs
D = Diameter in inches
SUPPORTS
Selection of supports
Following are major types of supports that are being used in piping design.
1. Simply resting the pipe on the structural member

2. U-Bolt
3. Pipe shoes
4. Stanchions
5. Rod hangers
6. Variable spring hangers
7. Constant spring hangers
8. Snubbers
Apart from the above supports following supports will be used while designing the piping system.
Anchor
Anchor is a support fixed in all six degrees of freedom (Dx,Dy,Dz,Rx,Ry,Rz).

It can be used to separate one piping system in to two for purpose of stress analysis.
Guide
Guides are used to limit the lateral movement of the pipe.
Limit stop
Limit stops are used to limit the axial movement of the pipe
Low temperature piping (up to 60oC) can be simply rested on the structural member as long as it is
not insulated. In order to avoid the pipe movement due to unexpected reasons, U-Bolts will be used in
cold piping.
When pipe is insulated, pipe shoe or stanchion or rod hanger will be used based on layout
requirement.
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When a pipe line expands vertically as a result of thermal expansion and it is not possible to provide a
rigid support then a spring support (variable / constant) will be used.
Rigid shall be used to resist dynamic loading. However if the piping system require flexibility to
accommodate thermal expansion, snubbers will be used. Snubbers acts as a rigid restraint when they
are subjected to suddenly applied loading but they do not resist static loads such as weight and
thermal loads.
Horizontal movement at hanger location will be limited in such a way that the offset angle from the
vertical axis does not exceed 4 deg. In case if horizontal movements is very large, hangers will be
installed in an offset position.
All the spring hangers will be in locked condition during Hydro test.
Variable Spring Hanger (VSH)
The supporting force in a variable spring varies with thermal movement and spring rate. Up to 40 mm
of thermal movement in vertical direction, VSH will be used. Apart from the movement, the load
variation between hot and cold condition will also be considered. If the load variation is less than 25%,
VSH will be used. For main steam, hot reheat steam and HP bypass systems, this variation is limited
to 10%.
If thermal movement is downwards,
Spring constant x Thermal Movement

% Load Variation = --------------------------------------------------------
Cold load + Thermal Movement
If thermal movement is upwards,
Spring constant x Thermal Movement

% Load Variation = --------------------------------------------------------
Cold load - Thermal Movement
Constant Spring Hanger (CSH)
Generally, if the vertical displacement due to thermal expansion is more than 40mm, a CSH will be
used. With CSH, the supporting force through out the thermal movement is constant. Also if the load
variation is more than 25% and nor VSH is available then also CSH will be used.
In some cases where the vertical displacement is less than 40 mm also CSH will be used to increase
the piping system flexibility and limit the terminal forces and moments with in the allowable limits
during operating conditions.
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ASME CODES
The American National Standards Institute’s standards used in the design of the Piping System are as
listed. ASME B 31. Code for Pressure piping is at present a non-mandatory code in USA, though they
are adopted as legal requirement.
ASME B 31.1 - Power Piping
ASME B 31.2 - Fuel Gas Piping
ASME B 31.3 - Process Piping
ASME B 31.4 - Pipeline Transportation System for liquid hydrocarbon and other Liquids
ASME B 31.5 - Refrigeration Piping
ASME B 31.8 - Gas Transmission and Distribution Piping Systems
ASME B 31.9 - Building Services Piping
ASME B 31.11 - Slurry Transportation Piping Systems
Of the above, the most commonly used code is ASME B31.3. Refineries and chemical plants are
designed based on the same. All power plants are designed as per ASME B31.1.
SELECTION OF LINES FOR STRESS ANALYSIS
As per code ASME B 31.1/B 31.3, no formal analysis is require in systems which
(i) Are duplicates of successfully operating installations or replacements.
(ii) Can readily be judged adequate by comparison with previously analyzed systems.
(iii) Satisfy the following equation specified by the codes.
Clause 119.7.1(A3)/ 319.4.1(c) specifies that no formal analysis is required in systems which are of
uniform size, have no more than two points of fixation, no intermediate restraints and fall within the
empirical equation.
DY
 KI
(L  U )2
where,
D = The outside diameter of pipe in inch (or mm)

Y = Resultant of total displacement strains in inch (or mm) to be absorbed by the Piping system.
L = Developed length between the anchors in ft.or (m)
U = Anchor distance, straight line between anchors in ft. or(m)
K1= 0.03 for USCS

= 208.3 for SI units
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As a general guidance, a line shall be subject to comprehensive stress analysis if it falls into any of
the following categories.
• All lines at design temperature above 180°C.

• 4" NPS and larger at design temperature above 130°C.
• 16" NPS and larger at design temperature above 105°C.
• All lines which have a design temperature below -30°C provided that the difference between the
maximum and minimum design temperature is above:
-190°C for all piping
-140°C for piping 4" NPS and larger
-115°C for piping 16" NPS and larger
• Note: These temperatures above are based on a design temperature 30°C above maximum
operating temperature. Where this is not the case, 30°C must be subtracted from values above.
• Lines 3" NPS and larger with wall thickness in excess of 10% of outside diameter. Thin walled
piping of 20" NPS and larger with wall thickness less than 1% of the outside diameter.
• All lines 3" NPS and larger connected to sensitive equipment such as rotating equipment.
However, lubrication oil lines, cooling medium lines etc. for such equipment shall not be
selected due to this item.
• All piping subject to vibration due to internal forces such as flow pulsation and/or slugging or
external mechanical forces.
• All relief lines connected to pressure relief valves and rupture discs.
• All blowdown lines 2" NPS and larger excluding drains.
• All piping along the derrick and the flare tower.
• All lines above 3" NPS likely to be affected by movement of connecting equipment or by
structural deflection.
• GRE piping 3" NPS and larger.
• All lines 3" NPS and larger subject to steam out.
• Long vertical lines (typical 20 meter and higher).
• Other lines as requested by the stress engineer.
• All production and injection manifolds with connecting piping.
• Lines subject to external movements, such as abnormal platform deflections, bridge movements,
platform settlements etc.
LOADS AND LOAD COMBINATIONS
Internal Pressure
Self Weight of pipe including fluid (Dead Weight), Weight of fittings and inline components
Temperature (Thermal Expansion)
Equipment Thermal Movement
Wind
Earth Quake (Seismic)
Water Hammer
Steam Hammer
Safety valve discharge
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American code for pressure Piping considers the above loads in following three load combinations.
(i) Sustained Loads

Pressure
Self Weight of pipe including fluid (Dead Weight),
Weight of fittings and
Weight of inline components
(ii) Occasional Loads

Wind
Earth Quake (Seismic)
Water Hammer
Steam Hammer
Safety valve discharge
(iii) Displacement Loads

Temperature (Thermal Expansion)
Equipment Thermal Movement
ANALYSIS METHODOLOGY
Stress analysis is performed between anchors for both static and dynamic loading conditions.
Static Analysis
Internal pressure load
Circumferential pressure stress is considered to calculate the minimum pipe wall thickness and stress
due to longitudinal pressure is evaluated with other sustained loads
Dead weight
Dead weight analysis is performed to provide adequate supporting in the piping system to prevent
failure from excessive sag and bending stress in the piping system. Analysis will consider the weight
of piping its contents, insulation and inline components in the piping system. Stresses due to weight
and internal pressure are combined for code compliance.
Thermal expansion
Thermal expansion stress is performed to provide sufficient flexibility in the piping system to prevent
failure from overstress of the material due to thermal expansion of the pipe and thermal movement of
connected equipment.
Hydro test load
For steam piping, apart from dead weight analysis, piping system is analysed for hydro test load
where the temperature of the piping system is considered as ambient and the pipe is filled with water
in order to calculate the hydrostatic loads and stresses.
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Dynamic Analysis
Seismic analysis
The input for seismic analysis of piping system is either dynamic (Response spectra) or static (Static
equivalent dynamic acceleration)
Static equivalent dynamic acceleration (static coefficient)

The static coefficient is typically a single horizontal acceleration value and a single vertical
acceleration value specified as a fraction or multiple of ‘g’ (Acceleration due to gravity) and is called
seismic design coefficient.
Static coefficient is calculated as per Uniform Building Code.
Wind
Piping which are located outdoors and thus exposed to wind will be designed to withstand the
maximum wind velocity expected during the plant operating life. Wind force is modeled as an uniform
load acting upon the projected length of the pipe perpendicular to the direction of the wind. Wind
pressure for various elevations will be used to calculate wind force using the following formula.
Fw = Pw x S x A
Where
Fw = The total wind force
Pw = The equivalent wind pressure
S = Wind shape factor
A = Pipe exposed area
Pressure relief valve discharge
Reaction forces from relief valve discharge is considered as an occasional load. The reaction force
due to steady state flow following the opening of safety relief valve in a open discharge installation
can be calculated in accordance with ASME B31.1 Appendix II and applied on the piping model as
static equivalent force.
Steam Hammer / Water Hammer
Steam hammer, the pressure surge generated by transient flow of superheated or saturated steam in
a steam line due to sudden stop valve closures shall be considered as an occasional load. Through
the flow is transient, for the purpose of piping stress analysis, only the unbalanced force along the
pipe segment tending to induce piping vibration will be calculated and applied on the piping model as
static equivalent force.
The reaction force due to sudden closing of a valve will be calculated as below.
F = Reaction force [N]

dP = peak value of increased pressure due to valve closing [N/m2]
d = pipe internal diameter [m]
r = fluid density [kg/m3]
L = pipe length between valve and reservoir [m]
U = fluid velocity before valve starts to close [m/s]
t = valve closing time [s]
tn = time for a shock wave to travel from valve to reservoir and back again [s]
a = sound velocity in actual fluid/shock wave velocity [m/s]
K = Bulk module of fluid [N/m2]
E = E-module for pipe material [N/m2]
Wt = Pipe wall thickness [m]
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CODE STRESS EQUATIONS
ASME B 31.1 specifies under clause 104.8 that to validate a design under the rules of this clause,
the complete piping system must be analyzed between anchors for the effects of thermal
expansion, weight, other sustained loads and other occasional loads.
(i) Stress Due To Sustained Loads
The effects of pressure, weight and other sustained mechanical load must meet the
requirements of the following equation.
SL = P Do + (1000) 0.75 iMA <= Sh in SI units.

4 tn Z
where,
SL = Sum of the longitudinal stresses due to pressure, Weight and other sustained loads, psi
(kPa)
i = Stress intensification factor. The product 0.75i shall never be taken as less than 1.
MA = Resultant moment due to weight and sustained loads,
in-lb (mm-N)
= [(Mx2 + My2 + Mz2)]1/2
Z = Section Modulus, in3 (mm3)
tn = Nominal Thickness, in (mm)
Sh = Basic allowable stress at the operating temp., psi (kPa)
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(ii) Thermal Expansion Stress Range
The effects of thermal expansion must meet the requirements of the following equation.
SE = 1000iMc <= SA in SI unit

Z
If Sh is greater than SL, following equation may be used.
SE = 1000iMc <= SA + f (Sh - SL) in SI unit

Z
Where,
SE = Expansion stress range, psi (kPa)
Mc = Range of resultant moments due to thermal expansion, in-lb (mm-N)
= [(Mx2 + My2 + Mz2)]1/2
SA = Allowable stress range, psi (kPa)
= f(1.25Sc+0.25Sh)
f = Stress range reduction factor
(iii) Stress Due To Occasional Loads
The effects of pressure, weights, other sustained loads and occasional loads including
earthquake must meet the requirements of the following equation.
PDo + 1000(0.75i)MA + 1000(0.75i)MB <= KSh in SI units

4tn Z Z
where,
K = 1.15 for occasional loads acting less than 10% of any 24 hr. operating period
K = 1.2 for occasional loads acting less than 1% of any 24 hr. operating period
MB = Resultant moment loading on cross section due to occasional loads.
QUALIFICATION OF PIPING SYSTEM FOR STRESS
Sustained Loads
The piping system is qualified for sustained load if,

1. The code stress is less than the code allowable stress
2. Sagging (Displacement in vertical direction) is less than 3.0 mm
3. Forces and moments (Loads) at equipment nozzle connections are less than the allowable
provided by equipment manufacturer or codes.
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What is the meaning if piping systems is not qualified for the above?
If the code stress due to sustained load is more than the code allowable stress or the sagging is more
than 3.0 mm or Loads at equipment nozzle connection are more than the allowable means the piping
system is not supported adequately.
What is the solution?

The solution is to add more rigid supports in the vertical direction.
Spring supports will also be considered as rigid supports for sustained loads because springs are
selected based on the sustained load (Weight of the piping system).
Theoretically rigid supports will be provided for qualification and based on the thermal expansion
stress analysis, rigid supports may be replaced by spring supports which will not affect the
qualification due to sustained loads.
What is the basis to add more supports.

Refer ASME B31.1, Table 121.5 for suggested support spacing.
What to do if the piping system is not qualified even after following ASME B31.1 ?
Look the displacement in vertical direction and find out the maximum. Add a support near to that
maximum displacement after checking the support feasibility.
Again run the analysis and check the results for stress and displacement. Keep adding supports near
to the maximum displacement until the system is qualified.
If forces and moments at equipment connections / terminal connections are more, add a support near
to the connection. It will reduce the forces and moments transferred to connections.
Thermal Expansion Loads
The piping system is qualified for thermal expansion load if,

2. Displacement in any direction does not cause interference with the adjacent piping or
equipment or structures.
3. Forces and moments at equipment nozzle connections are less than the allowable provided
by equipment manufacturer or codes
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If the code stress due to thermal expansion load is more than the code allowable stress or the
displacement is very high or Loads at equipment nozzle connections are more than the allowable
means the piping system is more RIGID.
The solution is to make the piping system flexible.
How a rigid piping system can be made as flexible?
1. Replace rigid supports in vertical direction by spring supports.

2. Introduce more bends in the piping system. Bends are more flexible than the straight pipe.
3. Introduce EXPANSION LOOP in the piping system
For an expansion loop to function, axial movement of the pipe on both the sides of the loop must
be restricted.
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4. Introduce EXPANSION JOINTS in the piping system.

Expansion joints can be used to increase the system flexibility. Expansion joints with out tie
rods will produce Pressure Thrust which need to absorbed by axial supports near to
expansion joints.
In order to avoid pressure thrust, Tied expansion joints can be used.
Occasional Loads
The piping system is qualified for occasional load if,
2. Displacement in any direction does not cause interference with the adjacent piping or
equipment or structures.
3. Forces and moments (Loads) at equipment nozzle connections are less than the allowable
provided by equipment manufacturer or codes.
If the code stress due to occasional load is more than the code allowable stress or the displacement is
very high or Loads at equipment nozzle connections are more than the allowable means the piping
system is more FLEXIBLE.
The solution is to make the piping system rigid by adding more RIGID supports in the direction of
maximum displacement.
What is the basis to add more supports.

There is no recommendation from code. Look the displacement in all the three directions and find out
the maximum. Add a rigid support near to that maximum displacement after checking the support
feasibility. When supports are added to reduce occasional stress, it should be ensured that the
thermal stresses are not affected. To achieve this, while locating the support for occasional load,
thermal displacement at the same point need to be looked at it. Ideally, support for occasional
loads is added where displacement due to occasional load is more at the same time thermal
displacement is less.
Once supports are added, run the analysis and check the results for stress, displacement and loads.
Keep adding supports near to the maximum displacement until the system is qualified.
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INPUTS REQUIRED FOR STRESS ANALYSIS.
ASME code to be used
Pipe properties
Outside Diameter
Wall thickness
Corrosion allowance (1.6 mm)
Mill negative tolerance (12.5%)
Material
Insulation properties
Material
Thickness
Density
Both pipe properties and insulation properties can be obtained from piping line list
Process parameters
Design pressure
Design temperature
Hydro test pressure
Process parameters can be obtained from Process & Instrumentation Diagrams (P&IDs) and piping
line list.
Ambient Temperature
Ambient temperature can be obtained from project technical specifications. In the absence of ambient
temperature in specifications, a value of 21oC shall be considered.
Page 24 of 29
Friction
For sliding supports, following friction coefficients shall be used.
Friction factor = 0.3 for steel against steel
= 0.1 for low friction pads, Teflon pads, PTFE.
Terminal movements with directions
Design horizontal seismic coefficient (Ah)
Wind velocity
Wind shape factor (0.7)
Pressure relief valve discharge
To calculate design pressure, exit velocity and reaction forces at discharge elbows and vent pipes of
open discharge installation, following inputs are required. These inputs can be obtained from project
specific safety valve data sheets and safety valve drawings.
Actual mass flow rate (Kg/sec) at the relief vale exit

Discharge elbow area (m 2)
Vent pipe area (m2)
Static pressure (N/m 2) at exit of elbow, inlet of vent pipe and exit of vent pipe.
Stagnation enthalpy at the safety valve inlet (KJ/Kg)
A Dynamic Amplification Factor (DAF) of 2.0 will be used.
Steam hammer / Water hammer
To calculate the reaction force due to sudden closing of a valve, following inputs are required. These
inputs can be obtained from Process and Instrumentation Diagrams (P&IDs) and project specific stop
valve data sheets.
Pipe internal diameter (m)

Fluid density (Kg/m 3)
Pipe length of each pipe segment (Stop valve to bend, bend to bend) (m)
Fluid velocity before valve starts close (m/sec)
Valve closing time (Sec)
Bulk modulus of fluid (N/m 2)
Young’s modulus of pipe material (N/m 2)
Pipe wall thickness (m)
A Dynamic Amplification Factor (DAF) of 2.0 will be used.
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CAESAR LOAD CASES
Load Qualification
SL # Load Case Description
Combination Check
01 (HGR) W - Hanger Load -
02 (HGR) W+D1+T1+P1 - Hanger Travel -
Hydro Test Condition Stress / Force /

03 (HYD) WW+HP+H -
(Hangers Rigid) Moment
Force / Moment /
04 (OPE) W+D1+T1+P1+H - Operating condition
Disp
Stress / Force /
05 (SUS) W+P1+H - Sustained Load
Moment / Disp
Operating (T1) + Seismic Force / Moment /

06 (OPE) W+D1+T1+P1+H+U1 -
along +ve X alone Disp

07 (OPE) W+D1+T1+P1+H+U2 -
along +ve Y alone Disp

08 (OPE) W+D1+T1+P1+H+U3 -
along +ve Z alone Disp

09 (OPE) W+D1+T1+P1+H-U1 -
along -ve X alone Disp

10 (OPE) W+D1+T1+P1+H-U2 -
along -ve Y alone Disp

11 (OPE) W+D1+T1+P1+H-U3 -
along -ve Z alone Disp
(OPE) Operating (T1) + Wind Force / Moment /

12 -
W+D1+T1+P1+H+WIN1 along +ve X alone Disp

13 -
W+D1+T1+P1+H+WIN2 along -ve X alone Disp

14 -
W+D1+T1+P1+H+WIN3 along +ve Z alone Disp

15 -
W+D1+T1+P1+H+WIN4 along -ve Z alone Disp
-
Seismic along +ve X
16 (OCC) L16 = L6-L4 ALGEBRIC
alone
-
Seismic along +ve Y
alone
Page 26 of 29
-
Seismic along +ve Z
alone
-
Seismic along -ve X
alone
-
Seismic along -ve Y
alone
-
21 (OCC) L21 = L11-L4 ALGEBRIC Seismic along -ve Z alone
-
22 (OCC) L22 = L12-L4 ALGEBRIC Wind along +ve X alone
-
23 (OCC) L23 = L13-L4 ALGEBRIC Wind along -ve X alone
-
24 (OCC) L24 = L14-L4 ALGEBRIC Wind along +ve Z alone
-
25 (OCC) L25 = L15-L4 ALGEBRIC Wind along -ve Z alone
-
(OCC) SRSS combination in X
26 SRSS
L26 = L16+0.3L17+0.3L18 (U1+0.3U2+0.3U3)
-
(OCC) SRSS combination in Y
27 SRSS
L27 = 0.3L16+L17+0.3L18 (0.3U1+U2+0.3U3)
-
(OCC) SRSS combination in Z
28 SRSS
L28 = 0.3L16+0.3L17+L18 (0.3U1+0.3U2+U3)
Operating (T1) + SRSS
Force / Moment /
29 (OPE) L29 = L4+L26 ALGEBRIC combination in X
Disp
(U1+0.3U2+0.3U3)
Force / Moment /
30 (OPE) L30 = L4+L27 ALGEBRIC combination in Y
Disp
(0.3U1+U2+0.3U3)
Force / Moment /
31 (OPE) L31 = L4+L28 ALGEBRIC combination in Z
Disp
(0.3U1+0.3U2+U3)
Operating (T1) - SRSS
Force / Moment /
32 (OPE) L32 = L4-L26 ALGEBRIC combination in X
Disp
(U1+0.3U2+0.3U3)
Force / Moment /
33 (OPE) L33 = L4-L27 ALGEBRIC combination in Y
Disp
(0.3U1+U2+0.3U3)
Force / Moment /
34 (OPE) L34 = L4-L28 ALGEBRIC combination in Z
Disp
(0.3U1+0.3U2+U3)
Sustained + Seismic
35 OCC L35 = L5 + L16 SCALAR Stress
along +ve X alone
Page 27 of 29
Sustained + Seismic
along +ve Y alone
Sustained + Seismic
along +ve Z alone
Sustained + Seismic
along -ve X alone
Sustained + Seismic
along -ve Y alone
Sustained + Seismic
along -ve Z alone
Sustained + Wind along

+ve X alone
Sustained + Wind along -

ve X alone
Sustained + Wind along

+ve Z alone
Sustained + Wind along -

ve Z alone
Operating (T1) –
45 EXP L45 = L4 – L5 ALGEBRIC Stress
Sustained
Pipe support reaction forces
These loads will be the basis for the pipe support design.
Design load for supports is calculated as maximum of forces due to,
Hydro Test Load

Sustained Load
Operating Load (Sustained + Thermal Expansion)
Operating Load (Sustained + Thermal Expansion+ Occasional loads)
STRESS REPORT
A typical stress report will indicate following details of stress analysis.
1. Design inputs specific to the piping system

2. Thermal modes considered
3. Analysis approach
4. Comparison of code stress results with code allowable
5. Comparison of equipment / terminal forces and moments with allowable
6. Conclusion
7. Stress isometric drawing
8. Caesar Input echo
9. Caesar output
Page 28 of 29
SAMPLE CALCULATIONS
Pipe Diameter = 400 NB

Outer Diameter = 406.4 mm
Wall thickness = Sch 120
Wall thickness = 30.96 mm
Ambient temperature = 21oC
Design temperature = 540oC
Design pressure = 120 Bar(g)
Material = A335 P22
Page 29 of 29

STRESS ANALYSIS OF PIPING SYSTEMS - VER01 - Viswanathan Sir

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A COURSE

2. Limiting deflections (sag) within the allowable.

3. Limiting the nozzle loads on connected equipment.

5. Evaluation of supporting requirements and their loads.

6. To find out unintentional disengagement of pipe from support.

Stress = Force or Load (N)/ Resisting Area (mm 2)

STRESSES IN PIPING SYSTEM

Longitudinal stress = P * 3.14 * Di2 / 4

2. Circumferential Stress (Hoop Stress)

From bending equation,

Bending stress (Sb) = MxC

Maximum bending stress (Sbmax) = M

The term I / R is called Section modulus (Z).

3.14 (Do4 – Di4)

Stress Intensification Factor (SIF)

Maximum Stress Intensity

STRESS – STRAIN RELATIONSHIP

Strain is the change in length of pipe to original length of pipe.

As per ASME B31.1

a) 1/4th of the ultimate tensile strength of the material at operating temperature

As per ASME B31.3

a) 1/3rd of the ultimate tensile strength of the material at operating temperature

ALLOWABLE FOR NOZZLE LOADS / TERMINAL POINTS

Centrifugal pumps – API 610 / ISO 5199

Positive displacement pumps – API 676

Centrifugal compressors – API 617

Reciprocating compressors – API 618

Steam turbines – NEMA SM23

Air cooled heat exchanger – API 661 / ISO 13706

Shell and tube heat exchanger – Manufacturer specification

Fired heaters - Manufacturer specification

Flat bottom welded storage tanks – API 650

Allowable force Fa = 100 * D

Allowable moment Ma = 200 * D

1. Simply resting the pipe on the structural member

Anchor is a support fixed in all six degrees of freedom (Dx,Dy,Dz,Rx,Ry,Rz).

Guides are used to limit the lateral movement of the pipe.

Variable Spring Hanger (VSH)

If thermal movement is downwards,

Spring constant x Thermal Movement

If thermal movement is upwards,

Spring constant x Thermal Movement

Cold load - Thermal Movement

Constant Spring Hanger (CSH)

ASME B 31.1 - Power Piping

ASME B 31.2 - Fuel Gas Piping

ASME B 31.3 - Process Piping

ASME B 31.5 - Refrigeration Piping

ASME B 31.8 - Gas Transmission and Distribution Piping Systems

ASME B 31.9 - Building Services Piping

ASME B 31.11 - Slurry Transportation Piping Systems

SELECTION OF LINES FOR STRESS ANALYSIS

D = The outside diameter of pipe in inch (or mm)

K1= 0.03 for USCS

• All lines at design temperature above 180°C.

LOADS AND LOAD COMBINATIONS

(i) Sustained Loads

(ii) Occasional Loads