PIPE STRESS ANALYSIS

1.1 Introduction : Pipe stress analysis training is intended to properly design a piping
system. And in order to properly design a piping system engineer must understand
both a system behavior under potential loading as well as the regulatory
requirements imposed upon it by the governing codes. System behavior can be
understood through various physical properties of the system such as
expansion,displacement , acc. Etc.
1.2 Reasons for performing stress analysis : Stress analysis is performed due to the
following reasons :
1.2.1 In order to keep stresses in the pipe and fittings within allowable levels.
1.2.2 In order to keep nozzle loading on attached equipment within allowable of
manufacture or recognized standards such as NEMA SA23,API610,API617etc.
1.2.3 In order to keep vessel stresses at piping connections within ASME SECVIII OR
to any other equivalent standard.
1.2.4 In order to calculate design loads for sizing supports and restraints.
1.2.5 In order to determine piping displacements for interference checks.
1.2.6 In order to solve dynamic problems in piping such as those due to fluid hammer,
transient flow, relief valve discharge etc.
1.2.7 In order to help optimize piping.
1.2.8 In order to comply with respective codes such as B31.1 etc
1.2.9 Welded attachment evaluation
1.2.10 Flange joint evaluation
1.3 Types of stresses induced in piping system
1.3.1 Primary stresses or sustained stresses
1.3.1.1 Longitudinal stress
1.3.1.2 Hoop stress Not considered while carrying out stress analysis as it always acts
parallel to the circumference of the pipe and always taken care of while deciding
thickness of pipe.
1.3.1.3 Radial stress Not considered while carrying out stress analysis as it is maximum
at the center of pipe and minimum at outerfibre of pipe which is just opposite to
the bending stress.
1.3.1.4 Bending stress
1.3.1.5 Shear stress
1.3.1.6 Torsional stress
1.3.2 Secondry stresses
1.4 Types of loads acting on piping system
1.4.1 Type of loads which causes primary stresses are listed below:
1.4.1.1 Weight of pipe ,fittings and components constituting piping system
1.4.1.2 Pressure (internal or external)
1.4.1.3 Weight of fluid
1.4.1.4 Snow weight
1.4.1.5 Hanger reactions etc.
1.4.1.6 Wind load
1.4.1.7 Seismic loads
1.4.1.8 Relief valve operation
1.4.1.9
1.4.2 Type of loads which causes secondary stresses
1.4.2.1 Thermal expansion
1.4.2.2 Anchor displacement
1.4.2.3 Equipment settlement
1.4.2.4
1.5 Comparison between primary loads and secondary loads

S.NO. Primary Loads Secondary Loads

1 Usually are force driven Usually are displacement driven loads
loads
2 Are not self limiting Are self limiting
3 Are non cyclic in nature.One Cyclic in nature.one load usually does not
time load can produce produce failure.
catastrophic failure
4 Goverened by strenght Goverened by fatigue and cyclic range
theory

1.6 Strenght theories

1.6.1 Maximum stress theory
1.6.2 Maximum shear stress theory (Tresca theory)
1.6.3 Von mises theory or distortion energy theory
For detailed study of stresses turn to attached section 1 general background on piping
analysis requirement and also a technical paper by MR . SRB

2.0 Performing stress analysis using pipsys

2.1 Introduction: Pipsys uses the stiffness approach to analyze systems subjected to
temperature changes from ambient ,prescribed displacement at restrained nodes, uniform
weight , and concentrated nodal loading.
In solving the static problem with the stiffness approach , the general equation takes the
form:

[K] {u} ={F}

where

[ K ] = global stiffness matrix

{ u } = global displacement vector
{ F } = global force vector
[ K ] matrix represents stiffness of element , six degrees of freedom of element ie three
translationals and three rotationals . Degrees of freedom of element are defined by type of
support provided and stiffnes of element is defined by geometry of element.
{ u } matrix represents movement of nodes in all three directions
{ F } matrix represents force vector acting on nodes in all three directions

For example

Consider an element with I node at one end and j node at other end then [ K ] is
represented as

[ K ] = [ kii kij ]
kji kjj
and displacement vector is represented as

{ u }= ui
uj
total equation is as follows
2.2 Input sheet
Input sheet is always prepared before preparing data file in pipsys . Copy of sample
input file is attached. Following points shall be taken care of when preparing input
sheet:
2.2.1 Before preparing input sheet check piping isometrics with respective piping and
instrumentation diagram .
2.2.2 Check material and schedule of each line . Properly mark the material and
schedule change in any particular line.
2.2.3 Check temperature and pressure of each element. Properly mark temperature and
pressure change in any particular line.
2.2.4 Insulation density shall be checked with manufacturer and variation in density
shall be considered.
2.2.5 Insulation thickness shall be as per manufactures given thickness.
2.2.6 Design pressure and design temperature shall be taken for analysis.
2.2.7 Check all the components constituting piping system are covered in piping
system.
2.2.8 Note down all references from where input sheet is prepared
2.2.9 Also note down all assumption made while preparing input sheet.
2.3 Creating data file for analysis
Data file is created using export option in Piping Design Workbench. Following
points shall be taken care of before exporting file to pipsys
2.3.1 Check all lines ,componets ,etc are there in the PDWB model.
2.3.2 Check for any discontinuity in the model specially at the joining points of two
files
2.3.3 Check junction points properly .
Once PDWB model is reviewed properly export option is used to creat data file . check
L/D ratio while exporting file to pipsys. L/D ratio helps in easy convergence of forces
and frequency.
2.4 Editing of data file
Before editing data file go through input format description for basic data . copy of
the same is attached. While editing following points shall be taken care of :
2.4.1 write down title & history of data file and if it is revised then write down reason
for revision
2.4.2 check all material cards as per input sheet
2.4.3 check all geometry cards as per input sheet
2.4.4 write down line ,valve,or any component identification with geometry cards in
short for easy reference
2.4.5 check element cards for proper assignment of material and geometry cards
2.4.6 In nodes and tangent point data known points should not have more than three
digits before decimal.
2.4.7 Before running file check no of elements ,no of node points etc . in the control
card.
2.4.8 Always keep in mind terminal point for any input in the basic input format
2.4.9 If there is some error while running data file it can be detected from OT1 file
created by pipsys.
2.5 Review of output file for deadweight analysis
The following points shall be reviewed carefully
2.5.1 check stresses at node points it shall be as minimum as possible
2.5.2 Check displacement in y-direction displacement shall not be more than 0.1inch.
2.5.3 there shall not be any positive displacement in y-direction if it there try to make it
negative.
2.5.4 Check displacement in other to axis .displacement shall be close to zero
2.5.5 Check loads on anchor points it should be negative.
2.5.6 Check loads on restraints. Loads shall be uniform on each restraint.
2.5.7 Check for stress intensifying factors value.
2.5.8 Check equilibrium table for nodes. Value at nodes shall be zero. Otherwise check
for any dicontinuity in the data fie
2.6 Review of output file for thermal analysis
2.6.1 check stresses at node points it shall not be more than allowable
stress value. Stress value shall be as per equation 12 of B31.1 POWER PIPING
CODE.
2.6.2 check loads on equipment. Loads shall be within allowable specified by
manufacturer or respective recognised standard.
2.6.3 Check for moments on equipments. Moments shall be within allowable specified
by manufacturer or respective recognised standard.
2.6.4 Range of load and moments shall be considered.
2.6.5 Check loads on restraints. It shall be permissible enough to design a structure
sipmle support.
2.6.1 Check equilibrium table for nodes. Value at nodes shall be zero. Otherwise check
for any dicontinuity in the data fie
2.6.6

3.1 Dead weight analysis:

Weight analysis is performed to provide sufficient stability in piping system. For
providing stability to system ,proper supporting is necessary. Proper supporting is
provided keeping in view all the following points:
3.1.1 supporting span shall be decided so that bending stresses shall be limited to
minimum (2300psi as per B31.1 POWER PIPING CODE). Note that this value is
suggestive only.
3.1.2 Also sagging shall be limited to 0.1inch (suggestive) as per B31.1 POWER
PIPING CODE.
3.1.3 Supporting span shall be calculated based on hydraulic load
3.1.4 Any drooping effects shall be eliminated.
3.1.5 Any leaning effects shall be eliminated or shall be minimum .
3.1.6 Avoid positive loads transfer on the equipments
3.1.7 Support shall be provided near to the equipment so that load transfer on
equipment is as minimum as possible.
3.1.8 Calculated horizontal span shall be reduced suitably near horizontal bend to
account for eccentric moments.
3.1.9 Calculated horizontal span shall be reduced suitably near verticle risers or
concentrated loads to account for moments created by point loads. Vertical risers
shall be considered a point load.
3.1.10 Always try to locate supports near to the following
 Concentrated load
 Horizontal bend
 Vertical bend
 Any component intensifying stress
3.1.11 Open discharge system shall always be anchored like
 silencer shall always be anchored
 relief valve open discharge shall always be anchored
3.1.12 draining requirement
3.1.13 slope
3.1.14 load distribution on supports shall be uniform
3.1.15 supports shall be structure simple.
3.1.16 Expansion joint shall be guides as per EJMA or equivalent standard.
For detail study of dead weight analysis turn to attached document MES-6.12 simplified
dead weight analysis
3.2 check following points while locating supports
3.2.1 check supports near to equipment. equipment removal for maintenace shall be
possible.
3.2.2 Check feasibility of support
3.2.3 If some component is removed pipe should be stable enough.
3.3 allowable variance in support location at site
allowable variance in relocating support is as per MES-6.1 based on WRC-316
Turn to attached documents
3.4 Common examples of dead weight supporting
 D/A

3.5 Interpretation of Power Piping Code( B31.1)

equation11,equation12,equation13
Interpretation here is intended to become familiar with various terms used in the different
equations and how these equations being used to carry out stress analysis.

3.5.1 equation 11
PDO I MA
+ < SH
4t Z

Where the first term in the equation is sustained longitudinal stress due to pressure , the
second term is sustained bending stress due to weight effects and term to the right hand
side of equation is allowable stress of material at hot condition.
The second term is calculated using dead weight analysis option in pipsys.
3.5.2 equation 12

PDO I MA I MB
+ + < k SH
4t Z Z

where first and second term are same as that of equation 11. The third term is bending
moments due to occassional loads .
factor k is used to increase the allowable stress value as the stress caused by occasional
load does not last long.
K= 1.15 for occasional loads acting for no more than 8hrs at any one time and no more
than 800 hrs /year
K= 1.20 for occasional loads acting for more than 1hr at any one time and no more than
80 hrs/year.

3.5.3 equation 13

iMC
< f (1.25 SC + 0.25 SH) + f (SA-SH)
Z

Where left hand term is bending stress due thermal expansion and any other kind of
displacement. The first term on right hand side is thermal stress range. The second
term is residual stress from equation 11.
F= stress range reduction factor for cyclic conditions for total no N of full
temperature cycles over total number of years during which system is expected to be
in operation .
MC = range of resultant moments due to thermal expansion.

4.1 Thermal Stress Analysis

If pipe is subjected to positive temperature change , it expands and thermal stress
induce in the pipe if free expansion of pipe is restricted. But as per the process
requirement pipe has to attached to some other pipe or equipment and thereby
restricting the pipe movement and hence stress is induced. How much stress induced
is enough ? This is governed by equation 13 of Power Piping code (B31.1). There
are different ways of reducing the thermal stress which are explained below.

4.1.1 Guided cantilever method

Pipe which expands and whose stress is intended to be reduced is termed as
expanding leg and pipe which is used for absorbing the thermal expansion is
termed as absorbing leg. Absorbing leg allows expanding leg to expand and hence
help to alleviate stress.

L1

L2
4.1.2 Loops
Providing loops in pipe runs is also an effective way of absorbing thermal
expansion and hence reduces thermal stress. Always start with square loop and
increase length in perpendicular direction to main run to further reduce stress.there
are different kinds of loops but mostly used loops are rectangular or square.

4.1.3 Expansion joints

Expansion joints is nothing but no of loops acting in series and usually used in low
pressure lines. It shall be tied so as to avoid thrust force acting on piping system.

For detail study on thermal analysis go through attached document MES-6.11

simplified flexibility analysis