ADNOC

5.2 Allowable stress

5.3 Displacement

Sagging

5.4 Displacement check

5.5 Support Force

5.6 Restrain Reaction

5.8 Over All Stress requirement

 Notes
90% expansion Load Cases
70% Sustain Load Cases
Displacement stress range should be 80% allowable stress during feed stage

_+20 mm for non rack piping within units in laterial direction

>20mm should check clashes with existing,new piping,structure

100 mm for pipes running in racks ,tracks,offsite area with in unit in axial direction
sustaing sagging shall be below 10 mm for process line
sustaing sagging shall be below 3 mm for Steam ,two phase and flare line
for slope line sagging shall nor exceed 3 mm

a. Is the value safe enough at each point’s displacement for pipe shoe falling?
b. Displacement at each point is not interfering adjacent piping or equipment.
c. Displacement does not make the slope of free drain line upside down.
d. The point with Y restraint is not lift off.
e. Deflection due to dead load is within the allowable value.

Displacement and load at the point of support and support adequacy shall be checked.
Spring hanger or spring support, displacement load and spring stiffness shall be checked in
compliance with manufacturer’s specification.

The calculated forces and moments at nozzle shall be in compliance with codes and standards /vendo
allowable (refer Appendix -A3)

Overall Stress Requirements

Detailed stress analysis carried out by the CONTRACTOR shall consider the following:
a. Pressure
b. Weight effects of piping components and fluids
c. Equipment and other sources of vibration
d. Thermal expansion and contraction
e. Stiffness variations and changes
f. Imposed Displacements
g. Shock loadings

External loadings on piping from applicable environmental conditions as follows, shall be included:
a. Wind loads
b. Seismic loads
c. Settlement
d. Frost heave
e. Snow loads
For existing plant modifications, the stress analysis shall also consider the following:
a. Mechanical modifications, for example, re-routing and / or extension to an existing piping system,
including changes in weight due to reconfigured valve or flange arrangements.
b. Temperature variations
c. Modifications to piping stiffness resulting from pipe wall thickness or material changes.
d. Material changes in connecting equipments (like columns, vessels etc.)
e. Process modifications (i.e. changes from original design conditions, including pressure,
temperatures and flow rate, or any transient conditions which may not have been considered in
the original design.
 Additional Notes
The piping flexibility and associated allowable expansion stress shall include consideration of the
resulting natural frequency of the pipework. Hence piping flexibility for thermal analysis should target
between 50% and 80% of the allowable stress.

if not possible shoe lenth should be design accordingly

Intermediate node should be created between two supports having max span to get max deflection
Thermal movements in long pipe run or where shoe extended shall be indicated in stress isometric
On sliding support ,expected Max displacement during operation shall be provide in each calculation

(refer Appendix -A3)

Detailed Stress Requirements

Forces and moments imposed by piping on equipment nozzles to which each pipe is conne
within the maximum allowable forces and moments as listed in .APPENDIX A3.
The imposed loadings at welded or mechanical connections, especially flanged joints, which would
result in leakage shall be evaluated.
The piping stresses developed due to Primary, Secondary and Occasional load cases shall be within
the allowable values defined in ASME B31.3 and applicable code.
The load cases analysed shall consider all viable and reasonable operating and design variations
which may occur during the operational life of the plant and are required by project scope.
Stress analysis shall be carried out on all critical piping systems as identified in Section 7.
Distortion in piping and valves or in connected equipment (for example, pump, compressors, turbines
etc.) resulting from thrusts or piping displacements shall be evaluated against allowable..
Stress analysis shall represent practical solutions, which avoid piping arrangements be sensitive to
pipe support positions, precise dimensions, pipe support functional requirements or small / limited fie
tolerances.
Piping and supporting arrangements shall be designed to avoid failure due to overstress or fatigue.
Piping and support arrangements with low natural frequencies (below 3 Hz) or which prov
excessive piping flexibility with susceptibility to ‘in service’ vibrations shall be avoided. Al
Section 11.3 for required piping system natural frequency for specific services.
Resonances due to machinery vibration or fluid induced vibration are avoided.
Appendix -A4
SWAY ANALYSIS METHODOLOGY FOR STRUCTURES AND EQUIPMENT

A4.1. Scope
This Appendix defines the design methodology to be followed for including the effect of w
sway on equipment / structures, on connected piping systems.

The main effects of wind on piping are summarised below:

a. Primary stress
b. Secondary stress due to wind induced sway on pipe rack / equipment

A4.2. Primary stress calculation

Primary stresses due to wind loading shall be calculated in accordance with ASME B31.3

A4.3. Secondary stress calculation

Sway check shall be performed for the following stress critical lines.
a. Flare headers (Branches to flare header in accordance with the following criteria)
b.Stress critical lines NPS 8 ( including insulation) and above on pipe racks

Equipment deflection shall be considered for tall vertical equipment’s like process columns. For
horizontal equipment and vertical equipment with large diameter to height ratio, like tank / others,
equipment deflection due to wind will not be significant and can be ignored.

For pipe racks, in a particular segment, deflection in transverse direction only needs to be considered
as deflection in longitudinal direction is generally insignificant for piping and may be ignored.

A4.4. Acceptance criteria

Acceptance criteria shall be in accordance with ASME Section III, Division I, NC-3653.2b

The stress due to the resultant moment from a time independent, single non-repetitive anchor
movement (for example, predicted building settlement, sway) is to be limited to 3 times of Sc (Basic
allowable stress at room temperature).

SIF (Stress Intensification Factor) may be ignored (i.e. considered as 1.0) if required for this occasiona
loading in line with ASME B31.3.

Sway deflection shall be considered in two principal directions north-south and east-west in two
separate stress checks, for example, when sway deflection is imposed on a pipe routed in north south
direction, the wind effect and sway deflection shall not be imposed on pipe routed in east west directi
16
FEED PROJECT STRESS ANALYSIS - MINIMUM REQUIREMENTS
General
The details provided in this section shall be used to define the piping stress activities carried out in
FEED (or basic engineering project stage) unless otherwise required and defined by the project scope
of work.

The piping stress work is envisaged to be carried out during FEED stage will not be to a detailed
engineering level due to the absence of key information, including vendor details.

The established FEED studies shall normally require piping materials, pipe routing, and pipe support
arrangements in conjunction with structural design studies, process function, and mechanical
agreements/specifications in order to demonstrate multi-disciplinary feasibility of the layout consisten
with the achievement of equipment nozzle loadings agreed with potential equipment Vendors.

At FEED stage, a particular attention shall be given to design the most critical piping routing in a prop
way to allow good flexibility using preliminary stress analysis as necessary and to avoid any major
changes during the detailed engineering stage

Stress Analysis
The stress analysis shall include the following:
a. Development of the critical line list to identify the lines for which stress calculations are carried
out during FEED and finalised when issued process information becomes available during the
Engineering phase.
b. Stress analysis calculations and assessments of piping which are critical to the development of
the overall plant layout (see below).
c. Stress analysis of all piping within tie-in scope to the level of detail required by the scope of work.
d. Definition of anchor points on pipe racks and the positions and number of expansion loops
required.

Note: This work will be in conjunction with piping and civil / structural groups to develop major struct
Unless otherwise required by the project scope, the following lines shall be analysed:
a. All lines connected to compressors, turbines and high pressure pumps
b. Lines NPS 18 and larger
c. Piping in AIV service
d. All Flare headers
e. Lines affected by wellhead displacement growth ( 50mm or more)
f. Lines which will be affected by significant deck or platform deflections and / or settlement
g. Lines with oblique connections
h. Lines with expansion bellows
i. Piping which will require to have a fundamental Natural Frequency equal and greater than 6 Hz
j. FRP lines larger than a NPS 6 unless specified otherwise for a project
k. All critical tie-in related lines larger than NPS 6
l. Lines assessed to be likely subject to slug flow.
m. Lines subject to dynamic pressure (?v²) exceeding the criteria specified in EI guidelines
n. Lines subject to the calculation of dynamic pressure (?v²) for which the stiff or medium stiff
requirement for the support arrangement as defined by the process study cannot be implemented
due to space constraint or due to the need of flexibility
11.6
Slug Flow
Lines which will be subject to slugging shall be identified on the line list and noted on P&ID’s.

For all lines that will be subject to slugging, Process shall provide, velocity, density data and slug type
assessments for the determination of slug forces.

Lines subject to slugging shall be identified in the critical line list and classified as L1 criticality level.

Slug forces shall be applied at changes of direction (not simultaneously to ensure the unbalanced
force effect) for the calculation of stresses and pipe support loads.

In the absence of accurate data during FEED stage , calculations of slug loads on 90 degree elbows
shall be based on the following simplified calculation which assumes equal inlet and outlet velocities
and zero difference in pressure between those points:

F1 = ρ・v2・A・(1-cos(θ)) ・ DLF [N] .

F2 = ρ・v2・A・sin(θ) ・ DLF [N]
Where:
DLF = 2
v = mixed phase speed [m/s].
ρ = liquid phase density [kg/m3].
v = slug velocity (1.2 x the average mixture velocity)
θ = the bend / elbow angle

Calculated unbalanced slug forces shall be included in the stress analysis for both metallic and nonme

Piping stress analysis shall incorporate axial restraints to absorb ‘slugging’ forces, preferably in all
changes of direction, to avoid unacceptable bending stresses.

The piping geometry of lines subject to slugging shall be routed with minimal changes of direction
which are not required to meet thermal expansion stress limits.

Particular attention shall be made to pipe supports and structures shall be designed to withstand
slugging loads and the combinations with those resulting from thermal effects.
10.2
Flange Leakage
All flanges (stress criticality L1) shall be checked for high bending moments that would tend to open
the flange and cause leakage. Calculation shall be performed where necessary to show moments are
acceptable. This should be carried out using CAESAR II® built in flange leakage evaluation
module.

Forces and moments applied to flange joints should be assessed in accordance with ASME
Section VIII, Division 1, Appendix 2 by considering the equivalent pressure method or by u
Section VIII Division 2 part 4.16 or ASME Section III, NC-3658.

Flange leakage criteria for API 6A flanges shall be in accordance with API 6AF.

Allowable loads at hub connectors and compact flanges shall be in accordance with ASME BPVC
Section VIII Div 1 Appendix 2 or VENDOR’s proven calculations considering external loads and
deflections from piping stress analysis and the stress shall not exceed 90% of the allowable.
10.3

10.5
Fatigue Analysis
The methodologies and standards proposed to be used for fatigue analysis shall be approved by
COMPANY prior to commencing work.

Fatigue analysis of complex geometric arrangements or sections, including flanges and fittings, and
items subjected to complex behaviour, for example, those occurring during cyclic loading conditions,
shall be carried out as per code.

When the total number of significant stress cycles due to all causes exceeds 100 000, fatigue
assessment rules in ASME B31.3 Appendix W shall be carried out.

In addition following fatigue analysis methods as applicable can be used as applicable with prior
approval:
a. The general recommended design procedure for fatigue analysis of piping systems is
described in the British Pressure Vessel Code PD5500 “Specification for Unfired Fusion
Welded Pressure Vessels’ Annex C which defines the S-N curves and contains methodology
for including all fatigue loadings (imposed movements, pressure transients, thermal gradients,
etc.) based on the Palmgren- Miner- rule fatigue damage calculation method.

b. For investigation of the fatigue effect from wave loading alone, the methodology listed in DNV
RP-C203 “Fatigue strength analysis of offshore steel structure”.

c. The Institute of Gas Engineers Code, IGE / TD / 12, “Pipework Stress Analysis for Gas Industry
Plant” for evaluation of high frequency fatigue caused by high gas and steam velocities
(acoustic fatigue).

High Pressure Piping Requirements

High pressure piping shall meet the requirements of ASME B 31.3, Chapter IX where specified on the
respective piping classes.

Allowable stress as per ASME B 31.3 Table K-1 shall be used in stress analysis

ASME B31.3 Chapter IX Fatigue Analysis - A fatigue analysis shall be performed on each piping
system, including all components, joints therein, and considering the stresses resulting from
attachments, to determine its suitability for the cyclic operating conditions specified in the critical line
list. The cyclic conditions shall include pressure variations as well as thermal variations or
displacement stresses.

ASME B31.3 Chapter IX Fatigue Analysis shall be in accordance with ASME BPVC, Section V
Division 2 or 3.
10.6
Pressure Relief
Safety relief valve discharge piping, for both open and closed systems, shall be designed to withstand
both the dead loads and the reactive or thrust loads with a dynamic load factor (DLF) = 2. This shall
consider the most severe case, for example, possible flashing conditions and liquid entrainment in
vapour flows.

Suitable supports shall be designed / installed in line with the good engineering practice to absorb
PSV discharge reaction forces (in order to prevent overloading and over stressing of the piping
system). In addition the calculated restraint loads shall be transferred to Structural group.

Relief valve reaction forces shall be considered as an occasional load in accordance to code. The
forces shall be determined using values taken from the instrument data sheet or VENDOR data.

Where this information is not available, relief valve discharge forces shall be calculated in accordance
with API RP 520 Part II.

Reaction force values from PSV discharges shall be included on the stress sketch and within the
stress report.
11.8
Pulsation
Pulsation forces shall be determined from information obtained from Process. Pulsation forces in a

piping system depend on the following:

a. Pipe diameter (Cross sectional area)
b. Process parameters
c. Molecular weight
d. Fluid density
e. Fluid properties

The predominant sources of low frequency pressure pulsation are:

a. Reciprocating / Positive displacement pumps and compressors generating oscillating pressure
fluctuations in the process fluid simply by virtue of the way in which they operate.
b. Centrifugal compressors generating the pressure pulsations at low flow conditions.

Pulsation events associated with rotating equipment shall consider the pipework upstream and
downstream to the first major vessel or volume.

The characteristics of pulsation events and associated acoustic modes respond to changes of
pressure, temperatures and molecular weight or fluid density and hence all operations scenarios (for
example, recycling, change in speed, running trains in parallel, change overs etc.).

Note: The full range of operating conditions should be obtained from Process and considered as part
of the assessment and included in consultations with equipment MANUFACTURER.
10.11
Steam Out
The steam out requirement, steam out temperature and the corresponding pressure is determined by
Process and this shall be taken from process line list.

In the case of the steam out procedure allowing steam to escape at an open end of the pipe, causing
jet force at the point, the piping shall be securely restrained at the steam exit point to ensure that the
loadings on the pipe and restraint system meet design limits.

Steam out temperature, where greater than process design temperature, shall be used in the stress
calculations to determine the expansion stress range and nozzle loads. The analysis shall also
consider whether the equipment and the piping are steamed out together or separately
10.4
Finite Element Analysis (FEA)
When Stress analysis will not provide a reliable stress solution or to carry out designs accurately
without conservative considerations, it shall be necessary to perform a finite element analysis (FEA)
with prior approval of COMPANY.

FEA for the part / components shall be carried out according to ASME B31.3 para. 304.7.2.
Note: In ASME B31.3 para. 304.7.2, reference is given to the ASME BPVC Section VIII, Division 2,
Part 5.

The contents of a Comprehensive FE Analysis report shall contain the contents listed below
applicable.
a. Executive summary which briefly describes the scope of the FE Analysis and the main
conclusions.
b. A description of the component explaining its intended use and functionality.
c. References to governing design specifications including relevant standards and applicable
pressure design codes.
d. References to project design premises, design requirements and a summary of applicable
loadings.
e. A detailed description of the analysed component geometry with references to associated detail
drawings.
f. A detailed description of any geometrical simplifications incorporated into the FEA model with
discussion of those effects on the accuracy of the analysis. This should include how fabrication
methods, tolerances and corrosion allowances are accounted for in the design of the component.
g. Material descriptions including designations details and applicable reference standard or
specifications. Details shall include material properties within the specified design temperature
range of the component.
h. A detailed description of the FE model discretisation, element types and sizes shall be discussed
with respect to the resulting accuracy, tolerance or limitations of the calculated stresses.
i. A description of load application and boundary conditions and associated colour plots.
j. A clear presentation of results in the form of coloured plots showing stresses and strains together
with plots of linearized stresses.
k. Code compliance check and clear conclusion of stresses and strains for the limit states, ULS,
ALS and FLS.
l. Relevant functionality checks in the applicable limit state.
m. Conclusions from FE model verification and load application including the check of reaction
forces.
n. For sample FEA Check list refer Appendix- A7 and shall be filled and attached with FEA report.
7.1
STRESS CRITICALITY SELECTION

L1 Lines - Comprehensive Analysis Methods

A comprehensive computer analysis shall be performed for L1 stress critical lines.
The latest version of CAESAR II® computer software, at the time of contract award, shall be utilized.
Complete calculation reports with contents listed per Section 8 of this specification shall, as a minimu
requirement, be prepared and submitted to COMPANY for review and approval.

The piping system shall be subjected to comprehensive stress analysis (L1), if it falls unde
following categories.
a. All lines according to Table 7-1 in conjunction with below requirements
b. All Lines in Toxic service, Lethal service , Category “M” fluid service (per ASME B313) and lines
designed to Chapter IX of ASME B31.3
c. All NPS 4 and larger lines with ASME class 900 or higher
d. All NPS 2 and larger lines connected to either rotating or reciprocating machinery or fired heaters
e. All lines NPS 3 and above likely to be affected by movement of connecting equipment or by
structural deflection, for example, lines subject to differential settlement or structural sway
f. All lines NPS 3 and larger connected to pressure relief valves and rupture discs
g. All lines NPS 3 and larger subject to steam ou
h. All lines NPS 3 and larger where engineered items are required for example, spring supports,
expansion joints, bellows, snubbers
i. All lines NPS 2 and larger connected to Reactors, Process heaters, Air coolers and strain
sensitive nozzles
j. All lines NPS 6 and larger, to and from static equipment.
k. Boiler feed water, steam lines to and from boilers and steam generators.
l. Lines with operating temperature below 5 Deg C with cold insulation or where engineered pipe
support for cold insulated pipe are required.
m. All lines 3” and above in steam, steam condensate and flare service.
n. All main Fire water network lines and connected lines.
o. All lines subjected to potential vibration due to mechanical, flow, acoustic or any other reason for
example, pressure surges, slug flow or water hammer, as listed in the EI Guidelines
p. All lines NPS 2 and above subject to two-Phase Flow or Multiphase flow or blowdown conditions
excluding open drains

q. All lines subject to wind loads as per this specification

r. All jacketed lines.
s. All FRP (GRE, GRP, etc) and other non-metallic lines pressurised line excluding sanitary &
irrigation lines
t. All lines routed on inter-platform bridges
u. All production / test and injection manifolds with connecting lines
v. All pressurised metallic underground lines networks NPS 6 and above (including closed drain
lines).
w. Lines of any size in cyclic service (regeneration / batch process) resulting in a stress range factor
f<1 per ASME B313 Fig 302.3.5;(i.e. greater than 7,000 cycles)
x. Flow lines connected to X-mas trees including headers and / or manifolds up to nearest anchor
or equipment.
y. All small bore lines connected with / to stress critical lines up to minimum two supports.
z. Lines reassigned by stress engineer from L2 and L3 categories
aa. Other lines as requested by the COMPANY stress engineer

L2 Lines – Simplified Analysis Methods

Stress approval by simplified methods, includes the use of charts, nomographs and simplified
formulae.
The results of the analysis using charts, nomographs or simplified formulae should be shown on the
stress sketch or isometric.

A simplified CAESAR II® analysis and report may be used in lieu of charts, nomographs or simplified
formulae. If this is used, the results shall be included in a simplified report with CAESAR native file
including the stress sketch or isometric and a computer output stress result and restraint summary.

All piping stress calculation notes of L2 lines shall be submitted to COMPANY for review along with
the source of the equations and / or charts used in the evaluation. For L2 category refer Table 7.1
below.
Piping Criticality Diagram Table 7.1

Table 7.1 shall be used to determine the Level of Stress Analysis required fo
Piping Criticality Diagram
relationship between Pipe Size and Temperature.
Table 7.1 shall be used to determine the Level of Stress Analysis required for al
Table 7.1 Criteria for Flexibility Analysis of Piping
relationship between Pipe Size and Temperature.
Table 7.1 Criteria for Flexibility Analysis of Piping
Design Temperature (oC)
Size
Less than or equal to

-30 and
NPS (in) 30 50 65 85 120 150 170 205 230 2
below

1 L1 L3 L3 L3 L3 L2 L2 L2 L2 L2

2 L1 L3 L3 L3 L3 L2 L2 L2 L2 L1

3 L1 L3 L3 L3 L2 L2 L2 L2 L2 L1

4 L1 L3 L3 L3 L2 L2 L2 L2 L1 L1

6 L1 L2 L2 L2 L2 L2 L2 L1 L1 L1

8 L1 L2 L2 L2 L2 L2 L2 L1 L1 L1

10 L1 L2 L2 L2 L2 L2 L1 L1 L1 L1

12 L1 L2 L2 L2 L2 L2 L1 L1 L1 L1

14 L1 L2 L2 L2 L2 L1 L1 L1 L1 L1

16 L1 L2 L2 L1 L1 L1 L1 L1 L1 L1

18 L1 L2 L2 L1 L1 L1 L1 L1 L1 L1

20 L1 L1 L1 L1 L1 L1 L1 L1 L1 L1

≥24 L1 L1 L1 L1 L1 L1 L1 L1 L1 L1

L3 - Neither manual nor computer analysis is generally required. A visual revie

drawing or sketch should be made to ensure that the piping system has fle

L2 - A simplified or approximate analysis method should be used.

L1 - A comprehensive computer stress analysis and stress report is required.

Note:
1) Criticality of piping connected to equipment is not included in the above table.
2) For offshore application due to space constraints, the above table shall be aligned w
company project specification
L3 Lines – Visual Inspection Analysis Methods
Stress approval by visual inspection should be applied to lines having adequate flexibility o
comparison with piping having a similar configuration that have been analysed using L1 or
L3 stress approvals are typically applied to utility piping with the exception of lines in steam
hydrocarbon utility service.

A formal analysis for criticality L3 piping is not required for the piping system th
following requirements:
a. Piping system which can be readily judged as being adequate by comparison with previo
analysed systems.
b. Piping, which is of uniform size, have no more than two points of fixation, no intermediat
restraints and falls within the limitations of the following empirical equation from ASME B31

D y
K1
(L  U )2

Where:
D = Outside diameter of pipe (mm)
y = Resultant of total displacement to be absorbed by the piping system (mm)
L = Developed length of piping between anchors (m)
U = Distance between anchors, straight line between anchors (m)
K1 = 208000 SA / Ea. (mm / m²)
SA = Allowable displacement stress range (MPa)
Ea = Reference modulus of elasticity at 21oC

This empirical equation represents no more than a rule of thumb. This accomplishes only a
check for simple basic layouts and shall not be applied in complex three-dimensional config
with multiple restraints and anchors or piping connected to sensitive equipment. Engineeri
must still be exercised.

All systems not meeting the above criteria, or if cannot be assessed confidently, shall be an
either simplified or Comprehensive methods. If CAESAR II® is used it is expected that a ‘th
analysis will be sufficient for such piping.
ess Analysis required for all lines based on the

s Analysis required for all lines based on the

nalysis of Piping

mperature (oC)
n or equal to

50 170 205 230 260 290 315 345

L2 L2 L2 L2 L1 L1 L1 L1

L2 L2 L2 L1 L1 L1 L1 L1

L2 L2 L2 L1 L1 L1 L1 L1

L2 L2 L1 L1 L1 L1 L1 L1

L2 L1 L1 L1 L1 L1 L1 L1

L2 L1 L1 L1 L1 L1 L1 L1

L1 L1 L1 L1 L1 L1 L1 L1

L1 L1 L1 L1 L1 L1 L1 L1

L1 L1 L1 L1 L1 L1 L1 L1

L1 L1 L1 L1 L1 L1 L1 L1

L1 L1 L1 L1 L1 L1 L1 L1

L1 L1 L1 L1 L1 L1 L1 L1

L1 L1 L1 L1 L1 L1 L1 L1

ally required. A visual review of the piping

at the piping system has flexibility.

hould be used.

d stress report is required.

d in the above table.

ve table shall be aligned with respective Group
ng adequate flexibility or by
en analysed using L1 or L2 methods.
xception of lines in steam and

the piping system that meets one of the

y comparison with previously

fixation, no intermediate
equation from ASME B31.3:

ystem (mm)

This accomplishes only a preliminary

three-dimensional configurations
ve equipment. Engineering judgment

d confidently, shall be analysed by

it is expected that a ‘thermal only’
General
All piping shall be considered as stress critical. However, due to mechanical and process reasons, not
all the piping has the same criticality. Stress criticality shall be assigned to each pipe in the Critical
Line List (CLL) see 7.2.

The criticality level listed below, shall be based on the criteria given in 7.3, 7.4, 7.5 and 7.6.
a. L1 - Stress Critical Line (Comprehensive Analysis Required)
b. L2 - Stress Critical Line (Simplified Analysis Required)
c. L3 – Non-Critical Line (Visual Inspection

The stress analysis of lines designated with a criticality of L1 shall be included in a comprehensive
stress report. All piping stress calculation notes, source of the equations and / or charts used in the
evaluation of lines designated with a criticality of L2 and L3 shall also be submitted for review.

The Critical Line List

A CLL is expected to be a key deliverable developed during the FEED phase and updated during EPC
phase.
Note: The CLL is an evolving document and should be updated at all stages of the project. This will
ensure correct and up to date data is being used to carry out the required levels of stress analysis.

The critical line list shall include and consist of the combination of Process, Piping and Str
information given in Appendix A1 based on its applicability to the project. The combination
agreed with COMPANY during the initial stage of the project.

The critical line list should be created using any suitable method which is efficient and reliable and
shall be in Excel format.

Any site modifications, changes in final VENDOR data for L1 lines shall be reassessed for
comprehensive stress analysis and the stress analysis reports shall be resubmitted for COMPANY

Performance Requirements for Critical Lines

Critical line design adequacy should be demonstrated during start up stage or during performance tes
list of such lines should be identified in the FEED stage of project and further developed or shall be de
lines shall be identified / annotated in Stress Critical line list

Typical lines to be considered shall include:

a. 2-phase flow lines with thermal flexibility requirements example Amine vertical piping to regenerat
b. Gas line with considerable pressure drop example PCV, BDV, etc.

c. Brownfield piping subject to FIV where flow capacity is increased by 10% or more
d. Any other critical lines identified like lines subjected to FIV and AIV, etc.
8.5
Pipe Supports Consideration
The supporting of the piping system shall be evaluated during the establishment of the piping layouts

The piping system shall be balanced, i.e. supported frequently in such a manner that ensures avoiding
high load concentrations and large pipe deflections.

Except the case of the spring supports or special supports, piping supports shall be included in the
piping stress analysis by considering them as rigid elements in the stress model.

In case of pipe “lift-off”, an additional piping model shall be created by removing the supports of the
pipework and follow-up by rechecking the results (i.e.: stresses, loads on equipment and forces
balance on the entire supports Alternatively, follow the method suggested in the Appendix S of B31.3

Stress analysis shall provide the maximum pipe support loads for design, from all load cases including
hydrostatic test.

Pipe support shall be provided in such a way that it shall take the load in all operation and shutdown
conditions.

Where possible, pipe supports shall be located on straight sections pipe. Pipe supports welded to pipe
bends or fittings shall be avoided wherever possible.
Note: Fittings have higher stress concentrations compared to straight pipe and the addition of suppor
has an undefined effect on the SIF value.

Where welding of trunnions on elbows cannot be avoided, the minimum wall thickness for elbows with
trunnions shall be Schedule 40. If less than schedule 40, reinforcement pad shall be provided in line
with Support standards.

Stress analysis shall include the stiffening effects of attachments welded to elbows.

Calculations shall be provided where welded or reinforced welded attachments are incorporated.
These calculations shall accurately represent the detailed configuration.

Trunnion support shall be modelled with the size and length matching the design, according to any of
the three methods of simulation shown in CAESAR II® Applications Guide manual.

Up to NPS 24 pipe size support shall be modelled at the centre of pipe i.e. radial expansion of pipe
shall be neglected and support shall be assumed to be acting at the centre of pipe and for larger pipe
24" and above model rigid element from the centre of the pipe to the bottom of the pipe up to the
supporting point considering the pipe radial expansion.

Valves supports provided for transportation shall not be used as pipe supports. Wherever due to spac
consideration & for large valves, designed valve support should be installed if required. These
supports shall be designed by valve manufacturer based on the calculated loads from stress analysis.
The requirement for bracing of small-bore branch connection piping NPS 2 and below, shall be
determined using the E.I. guidelines.

If the piping has removable spool, stress analysis shall ensure that the remaining part is independentl
and adequately supported.

Large diameter and / or thin wall piping ( D/t >96) shall be analysed to determine crushing loads at
supports and ensure suitable reinforcement pads/ wear pad are incorporated as required.

Pipe supports located on platform decks shall be locally reinforced and structurally supported.

Special attention shall be given to supporting piping made from FRP. VENDOR / MANUFACTURER
recommended spans and practices shall be used in determining the types of pipe supports required.

Allowable vertical and horizontal deflection limits specified in Structural specifications AGES-SP-01-
003 and AGES-SP-11-001 shall be considered in piping design/stress analysis.

Pipe supports which will be subject to vibration, shall be discussed with the civil / structural group, at
the initial stage of detailed design, to determine and agree the structural frequency limit and ensure
resonance is avoided.
Stress analysis shall ensure pipe support arrangements avoid the following:
a. Pipe support arrangements shall ensure mid span and overhang sag is within allowable limits
and maintains slopes defined on P&IDs or drainage requirements.
b. Long runs of piping without axial stops or guides.
c. Excessive loads at supports, restraining elements or supporting structures.
d. Destructive vibration due to any flow, acoustic or other reason.
e. Disengagement of piping from its supports.
f. Clashes between adjacent lines due to thermal expansion or contraction of the piping system.
g. Special supports requiring complex design details or impractical construction tolerances.
8.9
Spring Support
Lines incorporating spring supports shall be assigned as criticality level L1.

Stress analysis shall minimise the use of spring supports by careful consideration of support location
and alternative pipe routing.

Normal operating temperature shall be used to determine spring support set position however the loa
range shall be selected to accommodate maximum and minimum operating temperature

Variable type springs shall be selected to ensure the maximum load variation for all conditions does
not exceed 25%. Where that limit cannot be achieved, due to support displacements, "constant load"
type units shall be used. Maximum load variation for Constant spring shall be 5%.

Variable load type springs effecting sensitive equipment like for example compressors, turbine, etc.
shall have a maximum load variation of 10%. Where this value is be exceeded, "constant load" type
units shall be used.

Stress analysis shall ensure spring travel range includes potential contributing structural
displacements.

The automatic spring selection option within CAESAR II® shouldl be used wherever possible. Spring
support details may be manually selected where specific spring characteristics are required such as
those local to compressors, expanders and turbines.

Where manually selected spring selection is used, the reference VENDOR spring data shall be
included in the stress report.

Stress analysis of liquid filled piping connected to equipment and tanks and supported by spring
supports, shall include the WNC (Weight No Contents) load case and ensure nozzle loads are within
allowable limits for normal operating and WNC cases.

As a part of the work to determine the imposed piping loads a WNC (Weight No Contents) analysis
shall be carried out for each pipe where springs are positioned at rotating equipment’s like Pumps,
compressors, etc.) nozzles, a separate nozzle load check is required to cover the short-term spring
active condition where the line is empty (WNC) i.e. weight only’ analysis.

Where spring supports are located close to nozzles, the spring load shall also be determined with the
pipe released from the nozzle in all directions. This analysis will determine the ‘as-installed’ spring
support load settings and optimum support locations. When finalised, this analysis will be used to
demonstrates free flange alignments with the ‘as installed’ spring support settings is inherently
achievable and within API RP 686 allowable limits. This ‘weight only’ analysis will incorporate no
connection between the piping and compressor and model only the restraining effects and
directionality of the permanent pipe supports..
The maximum allowable angular movement of hanging springs (including any extension rods) shall
be limited to ±4 degrees between pivot points. Similarly pedestal type springs support should avoid
large spring bending by frictional force and displacement.

The CONTRACTOR shall develop and issue a spring support index / schedule with the required
information for design, installation, and adjustment procedure. This is essential for further performanc
monitoring of spring supports
8.1
Struts and Dampers
Lines requiring rigid struts and damper pipe support solutions shall be classified as L1 criticality.

The use of dampers shall be used with approval by COMPANY for the following application
a. To absorb dynamic loads, including vibration and to absorb two-phase flow forces, for example,
column piping in amine service, when pipe routing and other pipe support solutions are not viable.
Note: Selection shall include consideration maintenance requirements.
b. To provide a frictionless zero gap solution to provide lateral or axial restraints (or combinations),
which is easy and accurate to adjust.
c. Used at support locations to enable an easy form of adjustment for piping alignment including
around compressors, expanders and turbines.

The selected load / size rating of rigid strut units shall be a minimum of two times the calculated
maximum restraint loads.

Where rigid strut units are selected for use around sensitive equipment, the stiffness and angulation
shall be included in the stress analysis.

When a damper unit is selected, a ‘dead band’ of 3mm shall be incorporated into the stress analysis.
Note: This value represents the typical minimum displacement which will occur before a damper start
to function.

Stress analysis shall specify the end connection details for rigid struts or dampers.
Note: These are selected to provide long term functional restraint against vibration of repeated load
applications.
8.12
Modelling of Equipment
The calculation of equipment nozzle and pipe support displacements shall consider potentially
different coefficients of thermal expansion of the equipment material and connected piping.

For a piping system connected to static equipment (for example, vessels, exchangers) the effect of
shell expansion or contraction shall be considered in all direction. Shell expansion or contraction shall
be calculated separately, or the equipment included in the stress model as rigid element in all directio

For a piping system connecting with a pump, the effect of casing expansion or contraction shall be
considered by introducing the displacement in the stress model. The displacement at nozzle face due
to casing expansion or contraction shall be calculated separately or modelled as rigid element up to
the fixed point.

The nozzle displacements due to thermal conditions for large rotating equipment including
compressors and turbines, shall be taken from final VENDOR drawings.
 STRESS ANALYSIS CHECKLIST
The following typical checklist should be used, however, additional items shall be added /modified where included
to suit individual project specific stress analyses.

Project Name: Calculation #:

Sr. Item Y N N/A Remarks
No.
Basic Stress Input Data
1 1 Design Temperature(s) implemented?
2 2 Installation Temperature (21⁰C or as applicable)
implemented?
3 3 Solar Radiation Temperature(s) (85⁰C) implemented?
4 4 Design Pressure(s) implemented?
5 5 Operating Pressure(s) implemented?
6 6 Hydrostatic Pressure(s) implemented?
7 7 Piping Code (B31.3) implemented?
8 8 Pipe material(s) implemented?
9 9 Pipe size(s) checked?
10 10 Pipe wall thickness(es) checked?
11 11 Corrosion Allowance(s) checked?
12 12 Fluid Density checked?
13 13 Insulation thickness(es) checked?
14 14 Insulation Density(ies) checked?
15 15 Wind / Wave checked?
16 16 Displacements checked?
17 17 Pipe Supports checked?
Stress Analysis Criteria (Brownfield)
18 1 Mechanical modifications: Re-routing, pipe extension,
change in weight due to addition of flange, valve or
insulation?
19 2 Process modifications: Change in temperature, pressure,
flow rate or any transient?
20 3 Piping system experiencing excessive vibration?
21 4 Equipment-related problems: Distorted vessels, tank
connections, and pump or compressor alignment?
d where included
Project Name: Calculation #:
Sr. Item Y N N/A R
No.

A Remarks 22 5 Installation alignment problem?

Stress Analysis Criteria (Greenfield)
23 1 Line falls under category L1 of Table 7.1?
24 2 Line falls under category L2 of Table 7.1?
25 3 Line is NPS 4 and larger with ASME class 900 or higher?
26 4 Line is NPS 2 and larger connected to either rotating or
reciprocating machinery or Fired heaters?
27 5 Line is subjected to any kind of vibration due to either flow or
acoustic reasons?
28 6 Line is connected to pressure relief valves and rupture
discs?
29 7 Blow-down line NPS 2 and larger (excluding open drains)?
30 8 Line considered as flare piping?
31 9 Line NPS 3 affected by movement of connecting equipment
or by structural deflection?
32 10 Line is NPS 3 and larger subject to steam out?
33 11 Line crossing inter platform bridges?
34 12 Production / test and injection manifolds with connecting
piping?
35 13 Two-Phase Flow Piping such as blow down, steam
condensate and flare piping?
36 14 Process lines to and from centrifugal compressors and
blowers?
37 15 Boiler feed water, steam lines to and from boilers and steam
generators?
38 16 Line is either to or from static equipment?
39 17 A process line in toxic service?
40 18 Pipes subject to wind load as per this specification?
41 19 Line is either to or from gas or steam turbine?
42 20 Underground piping networks (such as fire water piping)?
43 21 Line is subject to external pressure due to vacuum or
jacketing?
 Calculation #:
Y N N/A Remarks

m
Project Name: Calculation #:
Sr. Item Y N N/A Remarks
No.
44 22 Line is designated as category “M” according to ASME
B31.3?
45 23 Flow line is connected to Christmas trees including headers /
manifolds up to nearest anchor or equipment nozzle?
46 24 Line is made of FRP(GRE, GRP, etc.)?
47 25 Long vertical lines (typical 10 meters and higher)?
48 26 Line is requested by the COMPANY?
Stress Analysis Special Conditions
49 1 Line experiencing steam out conditions?
50 2 If YES, was the steam out temperature used in the
calculation?
51 3 Line experiencing standby and operating conditions?
52 4 If YES, was the solar temperature considered for the standby
portion?
53 5 Line experiencing start-up and shut down conditions?
54 6 Is cold spring applied?
55 7 Does thermal bowing condition apply?
56 8 Does bourdon effect condition apply?
57 a If YES, is pipe length ≥ 60 m? OR

58 b Pressure ≥ 40 Bars and Size ≥ NPS 30?

59 c Alternatively, is the pipe made of FRP / GRP?

60 9 Any differential settlement conditions apply?
Stress Model Boundary Conditions
61 1 Is the piping model terminated at an anchor or a guided axial
stop (with no gap in the axial direction)?
62 2 If YES, does the model, unless it’s terminated by an anchor,
show the piping up to the next guide?
63 3 Is the piping system partially buried or connected to a buried
pipeline?
64 4 If YES, does the model include the buried portion up to the
nearest thrust block?
65 5 Is the piping system connected to any static equipment?
ation #:
N/A Remarks
Project Name: Calculation #:
Sr. Item Y N N/A Remarks
No.
66 6 If YES, were the calculated displacements of the equipment
nozzles included in the model?
67 7 Is the piping system connected to any rotary or reciprocating
equipment?
68 8 If YES, were the calculated displacements of the equipment
nozzles included in the model?
69 9 Does the model contain any pipe size ≥ NPS 6 having
branch size ≥ one third header sizes?

70 10 If YES, are these branches included in the model?

71 11 If YES, are these branched terminated by an anchor or a
guided axial stop (with no gap in the axial direction)?
72 12 Does the model contain pipe size ≥ NPS 6 having branch
size < one third header sizes?
73 13 If YES, do these branches fall under any of the criteria stated
in the “GREENFIELDS” section above and therefore
included in the model?
74 14 Package line: Are all the tie-ins anchored and / or have
allowable loads and / or displacements?
75 15 Is the CAESAR II® model showing the entire model to be
physically interconnected?
76 16 Does the “Title Page” contain all the line numbers included in
the model?
Dynamic Behaviour of Piping System
77 1 Is the piping system subject to slug flow?
78 2 If YES, was the spectrum analysis performed?
79 3 Is the piping system subject to fluid hammer?
80 4 If YES, was the spectrum analysis performed?
81 5 Is the piping system subject to pressure surge?
82 6 If YES, was the surge analysis approved by COMPANY
Process?
83 7 Were the surge pressures included in the analysis?
84 8 Is the piping system subjected to cyclic loading?
85 9 If YES, was a fatigue evaluation carried out?
ation #:
N/A Remarks
Project Name: Calculation #:
Sr. Item Y N N/A Re
No.
86 10 Does the piping system contain any relief valves or rupture
discs?
87 11 If YES, was a spectrum analysis carried out?
88 12 Were the natural frequencies for the piping system
determined?
89 13 If YES, how much is the lowest of these frequencies?
90 14 Does the piping natural frequencies and excitation
frequencies separated by more than 20%?
91 15 Were brace supports added to branches ≤ NPS 2 in ASME
class ≥ 300?

92 16 Were the recommendations of the AIV and / or FIV study

incorporated?
Piping System Supports
93 1 Do any of the pipe guides have a special gap (> or < 3 mm)?
94 2 If YES, is this gap value shown in the stress isometric?
95 3 Are trunnion supports properly simulated?
96 4 Are friction coefficients properly selected?
97 5 Is there a spring within 4 pipe diameters after the equipment
nozzle?
98 6 If YES, were the restraints at that nozzle released?
99 7 How much is the spring vertical movement (mm)?
100 8 How much is the maximum load variation (%)?
101 9 Are there any expansion joints in the model?
102 10 Was the use of such expansion joint approved by
COMPANY?
103 11 Was that expansion joint modelled automatically by
CAESAR II®?
104 12 Was the piping arrangement involving that expansion joint
reviewed by the joint Manufacturer?
Special Design Considerations
105 1 Is any part of the piping system subjected to either platform
or deck deflections?
 Calculation #:
Project Name: Calculati
Y N N/A Remarks
Sr. Item Y N
No.
106 2 If, YES, were the proper magnitude and direction of platform
or deck deflections considered in the model?
107 3 Were the calculated nozzle loads verified against the
appropriate standard shown in Appendix A3?
108 4 If YES, was that check performed via CAESAR II®?
109 5 If NO, were the calculated nozzle loads verified against
Vendor data?
110 6 Was the misalignment check carried out for the equipment
nozzle?
111 7 If YES, was it found to be within the acceptable limits?
112 8 Was the flare header analysed considering the appropriate
liquid content?
Miscellaneous
? 113 1 Was the stress analysis for the GRE / GRP carried out by
Manufacturer and endorsed by contractor?
114 2 Do the tie-in numbers appearing on the P&ID’s appear in the
stress model as “Node Name”?
115 3 Do the displacements of the tie-in point(s) in this model need
t to be transferred to another model?
116 4 If YES, which tie-in point? And to which model?
117 5 Were the displacements of the tie-in point(s) in this model
extracted from another model?
118 6 If YES, which tie-in point? And from which model?
119 7 Are the requirements of Small bore piping as per Appendix
A1 of AGES-SP-09-001 fulfilled?
CAESAR II® Requirements and Results Evaluation
120 1 Is the utilized version of CAESAR II®, at the time of contract
awarding, applying the contractually agreed revision of
ASME B31.3?
121 2 Does the Contractor certify that the proposed load cases
reflect ALL possible scenarios of operation?
122 3 Were the “SIF’s and Stresses” configuration parameters
found to be in compliance with COMPANY requirement?
123 4 Is there any Stress Ratio exceeding 90% of the allowable
stress?
 Calculation #: Project Name:
Y N N/A Remarks Sr. Item
No.
of platform 124 5 Are the horizontal and vertical displacement values within
acceptable levels?
t the 125 6 If NO, specify value and node number.
126 7 Is the vertical load variation between the sustained and the
®? operating cases exceeding 150%?
against 127 8 Were ALL the applicable flanges assessed for flange
leakage?
quipment 128 9 If YES, was this assessment carried out using CAESAR II®
flange leakage module?
mits? Stress Analysis Report
ppropriate 129 1 Was the preliminary stress native input files submitted?
130 2 Were the relevant data sheets and / or Vendor drawings
submitted?
ed out by 131 3 If YES, were the nozzle allowable loads (3 forces and 3
moments) shown in the drawing?
ppear in the 132 4 Was the final report, containing all the relevant data,
submitted along with the final stress files?
model need

his model

?
r Appendix

of contract
ion of

d cases

meters
ement?
allowable
 Calculation #:
Y N N/A Remarks

ement values within

.
he sustained and the

essed for flange

ut using CAESAR II®

ut files submitted?
r Vendor drawings

ds (3 forces and 3

relevant data,
les?
8.14
Stress Analysis Report – Format and Contents
The Stress input file, in its native format, shall be submitted electronically to COMPANY for review
and approval.

The following should be included in Stress analysis report, as applicable, but not limited to
a. Introduction
b. System description / limits in terms of boundary conditions / methodology used for stress analysis
specifying the software version, line numbers involved etc.
c. Design Input parameters including specific process information like velocity, density of 2 Phase
flow, etc.
d. Load Cases including narrative description of all foreseen load cases and modes of operation
e. Assumptions & boundary conditions
f. Reference document number for Piping loads communicated to Structural / Civil

g. Summary of Calculations ( with relevant node numbers) as applicable including:

? Trunnion check
? Slug force / surge force and vector calculations
? API tank settlement vectors
? PSV reaction force calculations
h. Special support reference details

i. Result summary
? Stress summary including Maximum Code stress vs. Allowable stress for all applicable
load cases
? Maximum equipment nozzle loads vs. Allowable loads
? Maximum restraint forces & moments
? Maximum displacement summary
? Modal analysis results if any
? Spring hanger reports
? Results of Flange leakage Calculation
? Any other Calculation like WRC 107, etc. including those listed in ‘g’ above

j. Recommendations & Conclusion

k. Appendix should contain the following
? Marked up P&ID & Line list ( extracted)
? CAESAR II Plot showing Nodes & Restraints
? Stress isometrics mark-up
? Detailed CAESAR II reports including Input & Output Listing
? Other relevant vendor details & reference calculations like equipment drawings, Valve
details spring details, Expansion bellow details, Non-standard flanges, hub connector,
etc.
Stress Isometrics shall be included in the stress report and include the following details as
but not limited to:
a. Node numbers
b. Line numbers
c. Line size / thickness
d. Dimensions
e. Temperature and Pressure conditions
f. Material
g. Piping class
h. Support types (at all support location, in case of guide support or axial stop gap should be
mention if varying from standard gap)
i. Plant north
j. Global axis
k. Support function
l. Spring support details
m. Expansion bellows details
n. Special component details and weights
o. Nozzle thermal displacements
p. External / calculated loads and applied nodes
q. Special notes ( if any)
9.2
Stress Intensification Factors (SIFs)
Stress analysis of piping systems shall include stress intensification factors to ensure that the system
is safe, fit for purpose and that all stresses are within the ASME B31.3 code allowable values.

SIFs for standard components are available in ASME B31.3 Appendix-D and ASME B31J and
same shall be used. .

User defined SIFs shall be used when determined by FEA or obtained from previously reliable
information which satisfies ASME B31.3 requirements for components not available in ASME B31.3
Chapter D or ASME B31J

Where fabricated lateral tees are used in process piping systems, accurate and representative SIF
values shall be determined by FEA and satisfy ASME B 31.3 Appendix D and ASME B31J
requirements.

The flexibility factor and SIFs for branches and tees for lines that have a D / t ratio >100 shall be
determined by FEA or other alternative methods and shall be approved by COMPANY. Such
calculations shall be included in the stress report.

SIF correction values for large diameter thin-wall bends, shall be accounted for in the analysis in
accordance with ASME B31.3 Appendix D, Table D300 or ASME B31J
9.3
Wind Case Analysis
Wind loads shall be applied at maximum operating temperature.

Wind Loads etc shall be determined in accordance with Structural Design Basis - Onshore AGES-SP01-

Wind loading shall be applied to piping 10m above site grade or wave datum for offshore applications

A wind shape factor of 0.7 shall be considered in wind analysis of piping for pipes where the outside
diameter (including any insulation) > NPS 8 (200mm).

The effects of shielding by the structure and piping should be considered as applicable.

The prevailing wind shall be considered as acting North-South and East-West, and independently, not
simultaneously. Wind profile (velocity / pressure versus elevation) shall be in accordance with
Structural Design basis and shall be used for calculating the wind effect in applicable piping systems

The maximum occasional loads shall be considered as operational (OPE in CAESAR II®) and shall
include the combined effects of weight + pressure + thermal + wind (W + P + T + wind). Stress analy
shall include structural movements and accelerations caused by wind where applicable.
9.4
Seismic Case Analysis
When calculating the seismic loads, the full operating content of piping shall be included.

Stress analysis shall include `g' forces aligned with the respective site location based on
geographically applicable seismic parameters in accordance with Structural design basis, AGES-SP01-

Stress analysis of seismic conditions shall normally be carried out using statically applied g forces.

The use of response spectrum data shall be restricted to arrangements for which the static method
cannot achieve reliable or acceptable results.

Seismic loads shall be considered as acting in the Horizontal orthogonal axes and not acting
simultaneously. Vertical seismic component as per ASCE 7 should be applied as applicable. In such
case, the load cases provided in Appendix A4 shall be adjusted to suit the vertical seismic component

The largest pipe restraint loading cases may result from seismic conditions and these calculated
loadings shall be provided to structures to ensure full compliance with structural design.

The maximum operating temperature shall be used when determining maximum seismic plus
operating loadings.
9.6
Transportation
A separate stress analysis shall be carried out to assess the effect of all forms of transport
determine any additional pipe support requirements in piping and at nozzle disconnection

During detailed engineering phase the differential displacement due to transportation of module / dec
shall be considered in transportation analysis. The values shall be defined by the structure studies.

The maximum displacement stress range shall be checked according to ASME B31.3 requirements.
CONTRACTOR shall provide a method explaining the differential displacements considered with the
justification of their value.

The stress analysis will determine if additional pipe supports are required to control and locate piping
which is unconnected to sections in other modules. These additional supports are termed
“transportation supports”. Such supports forms rigid vertical and lateral restraints and will usually
incorporate ‘Hold-Down’ features.

Transportation supports shall be part of the permanent design where possible. The objective is to
minimise complexity of onsite support removals once the module(s) / skids has been installed.

If pipe supports are required specifically for transportation, they shall be clearly identified on the Stres
Isometrics as transportation supports .The final design should consider easy identification ( like
separate colour) with a specific tag number for removal prior to Mechanical completion. Final as-built
isometrics drawings shall be without any transportation support. .Piping restraint loadings may vary
significantly and be in positions which occur during operation. The allowable structural stress for
transportation is also different from operational loadings. Accordingly, transportation loads at all pipin
support positions shall be evaluated and transmitted to the structural group.
Units
SI Units shall be used in CAESAR II for stress calculation and documentation.

Table 1.2 Units of Measure

System of Units
Description SI Units FPS U
Force N lb.
Moment Nm lb.ft
Stress MPa psi
Pressure barg psig
Temperature °C °F
Movement mm Inch
Nominal Pipe Size, NPS mm inch
Length mm inch
Density kg / m3 Ib / in
 and documentation.

ure
s
SI Units FPS Units
N lb.
Nm lb.ft.
MPa psi
barg psig
°C °F
mm Inch
mm inch
mm inch
kg / m3 Ib / in3
6.5
Pressure
Stress analysis shall calculate stresses in each component considering the most severe design
pressure conditions expected, as indicated in the process line list and CLL.

Test pressure and weight of testing fluid shall be included in stress analysis load cases. Th
of pipe supports shall consider the weight of the pressure testing fluid if greater than the

External pressure shall apply to piping where the internal pressure is below atmospheric p
to process conditions, as noted on the Process line list as “vacuum”. In this case full vacuu
assumed.

Where external pressure in excess of full vacuum may exists, for example, in jacketed piping systems
all loading conditions including test pressure shall be considered.
6.4
Temperature
In accordance with ASME design codes the primary temperature for stress analysis shall [PSR] be
based on design temperature.

Maximum and minimum design temperature shall be obtained from the Process line list and
shall be reflected in Critical line list.

The operating temperature is determined by process engineering and shall be taken from the process
line list. Process shall also provide values for maximum and minimum operating temperatures. These
represent temperature variations which could occur throughout plant operations and lifecycle.

Stress analysis shall be performed for the temperature range which is the algebraic differe
maximum design temperature and minimum design temperature.

The temperature for the occasional conditions for example, start-up, cool-down, shutdown,
regeneration, depressurization, fire case scenario, steam-out condition, decoking, compressor recycle
temperature drop resulting from pressure relief / depressurisation and other special conditions shall
also be considered. This temperature shall be taken from the Process Line List and shall be specified
in the Critical Line List.

For design temperature of heat traced, refractory (lined) and jacketed piping refer to sect
10.17 and 10.18.

Maximum and minimum design temperatures shall be used to determine maximum pipe su

The thermal displacement of equipment nozzles shall be calculated using the relevant des
temperature.

For lines operating above 0°C, an installation temperature of 21ºC for all COMPANY faciliti
used. For lines operating below 0°C, an installation temperature of 40°C shall be used.

For above-ground uninsulated metallic pipe, the solar radiation temperature for all ADNOC
COMPANY facilities shall be taken as 85°C.

For underground lines, the max operating temperature or the maximum soil temperature w
higher shall be considered
6.6
Piping Material Class / Specification
Piping Stress analysis shall incorporate piping information from the Piping Material Specification
AGES-SP-09-003 and Project Piping Material Specifications as applicable. This information will also
be used by and conform with, piping design, be a part of every line number and listed in the Process
Line List and Critical line list.

Piping stress analysis shall be based upon the following:

a. Piping material Specification / Pipe class
b. Nominal Pipe Wall thickness
c. Corrosion allowance
d. Branch connection details taken from individual Piping Material Classes.

Note 1: Branch connection types listed in the PMC are determined based primarily on area
replacement.
Note 2: Branch connection types may be changed to reduce SIF values if required
6.7
Weights and Dimensions
It is critical for the weights and dimensions of piping components to be modelled accurately and
included in pipe stress calculations.

ASME pipes, fittings and flanges - The weight and dimensions of piping components shall be taken
from the relevant ASME standard or CAESAR II® library. Wall thicknesses shall be obtained from
appropriate PMC details.

Non ASME flanges - For API, compact and non-standard flanges as well as hub connectors, weight
and dimensions shall be taken from Vendor drawings where available. Until such data is available,
preliminary calculations or VENDOR catalogue should be used.

Valves - Until actual VENDOR drawing dimensions and weights are available, this information shall
be taken from the CAESAR II® library or Vendor catalogue. Weight of the gear box or actuator shall
be included. For the instrument tagged items, the weights shall also be supplied by Vendor. The final
stress analysis report shall incorporate actual valve data including actuator weight.

Non-standard items - The weights of all non-standard items incorporated with individual analyses shal
be listed on the associated stress sketch.

Insulation- The weight of all insulation shall be included in piping stress analysis. The weight of
insulation shall be determined accurately using confirmed layer thickness and densities including the
weight of internal and external metallic layers and cladding. The analysis of piping with cold
preservation insulation shall include the weight of contraction joints and valve boxes which are not
independently supported.

Pipe supports - The weight of pipe support components if acting as an additive load on the piping
system, shall be included in the pipe stress analysis and in restraint load values.
6.3
Process Design Conditions
The Process line list contains all design, operating and upset / transient temperatures, pressures and
density data. This information shall be included in the Critical Line List (CLL) and incorporated into
piping stress analyses to determine the most severe conditions on piping and loadings on equipment.

If not available from the Process line list, information relating to flow conditions which pro
requiring stress analysis and / or specific pipe support requirements shall also be obtained
project Process team. These include the following:
a. Slug flow
b. 2 phase flow / Multiphase flow
c. Surge
d. Acoustic Induced Vibration (AIV)
e. Flow induced Vibration (FIV)

A list of lines which will be subjected to more than one cycle of operation per day or greater than 7000
cycles total during the life of the plant, shall be obtained from Process.

For the list of lines described in 6.3.3, coincident temperatures and pressures including the expected
number of full and partial cycles, including upset and transient conditions, during operation shall be
obtained from Process.
8.4
Stress Modelling Considerations
Stress models shall be kept to a minimum size which accurately represents the connectivity and pipe
support arrangement of the piping system to be analysed whilst maximising the efficiency of the over
system analysis.

The set of line numbers in the model, together with representative to and from nodes, shall be
identified on the title page of Stress File.

The extent of the modelling shall include the following considerations, the system under consideration
together with accurate representations of piping or equipment connectivity outside of the system und
analysis. Terminations of stress analysis models shall ensure the behaviour, deflections and effect of
restraints on the piping shall be correctly defined, realistic and practical. The objective is to ensure th
stresses and restraint loadings calculated are accurate.

Stress models shall be terminated with an anchor or the next guide after a guided axial st
gap in the axial direction) in order to accurately represent the system analysed.

For a stress critical piping system of NPS 6 and above, the branch connections from 1 / 3 o
NPS up to the header NPS, shall be included in the stress analysis. The branch shall be ter
at the first anchor and / or guided axial stop. If the branch size is less than 1 / 3 of the hea
then stress critical lines criteria shall prevail. However, as a minimum, associated small-bo
shall be modelled up to the second support.

Where ASME B31.3 piping interfaces with ASME B31.4 / ASME B31.8 pipeline other applicable codes,
model boundary conditions shall be based on pipeline system loads and deflections at the interface.

If a piping system is partially buried or connected to the underground piping, the effect of buried
pipeline over the above ground piping shall be considered. The underground piping shall be included
in the analysis up to the nearest thrust anchor block point. In the absence of a thrust anchor, the burie
model shall be extended up to 2 changes of direction or a virtual anchor position.

All concrete wall penetrations with puddle flanges shall be considered as anchors. In the case of
sleeves i.e. without puddle flange the point of vertical or lateral support shall be considered to be a
sliding restraint. The extent of the system modelled shall continue up to the next anchor or guided
axial stop location.

Directly buried piping under plant road crossing (without sleeve / culvert) should be considered as an
anchor point.
8.6
Pipe Spans
Piping spans should consider the following criteria:
a. Maximum bending stress of 50% of the longitudinal stress (ASME B31.3: Sh)
b. Indentation stress at support locations
c. Allowable loads at support location
d. Lowest fundamental frequency of 4 Hz or greater.
The maximum mid-span deflection shall be limited as specified in 5.3.3
8.7

Table 8.1 Friction Coefficient

Material Friction Coefficient
Proprietary low friction sliding surfaces or According to VENDOR data but not
coating ( e.g. Teflon) less than 0.1
Carbon steel on carbon steel 0.4
Steel on concrete 0.6
Stainless steel on carbon steel 0.3
Friction
Friction coefficient shall be considered in the stress calculation at all pipe supports, in accordance with
Table 8.1 and the requirements of Structural Design Basis AGES-SP-01-003.

Table 8.1 Friction Coefficient

Material Friction Coefficient
Proprietary low friction sliding surfaces or According to VENDOR data but not
coating ( e.g. Teflon) less than 0.1
Carbon steel on carbon steel 0.4
Steel on concrete 0.6
Stainless steel on carbon steel 0.3

Stress analysis shall minimise the requirement for low friction sliding surfaces. These items shall be
avoided at locations where inspection / maintenance and replacement is impractical. If a low friction
sliding surface is incorporated, the coefficient of friction value for aged-sliding surfaces shall be
obtained from the VENDOR and used in the design
Note: Low friction sliding surfaces deteriorate over time and lose its original function and low friction
characteristics.

Code stress checks and actual piping forces and moments for equipment nozzles qualified with and
without friction factor at pipe supports.

Axial and lateral restraint loads transferred to structures and used for structural design shall not
consider any advantage of proprietary low friction pads (like Teflon).

For all pipe supports affecting sensitive equipment, friction shall be considered to act on all active
faces of each pipe support.

Stress analysis shall identify positions on stress sketches, where calculations require low friction slide
plates.
8.8
Pipe Support Gaps and Hold Downs
Stress analysis shall assume standard pipe support gaps of 3mm.
Unless specified otherwise, on issued isometrics and pipe support details, stress analysis of
brownfield piping shall be modelled to incorporate standard 3mm gaps.

The use of non-standard pipe support gaps and gaps that differ between faces shall be avoided.

However, if required for analysis, the gaps shall be shown on the stress sketch.

Where hold-down supports are required, stress analysis shall identify the positions on stress sketches
Note: Hold down supports are used to stabilize piping subjected to dynamic effects including FIV, 2
phase flow, pulsating flow and transportation.
 CRITICAL LINE LIST (CLL) - REQUIRED CONTENTS
The Critical Line list shall be created using a combination of information contained in the Pr
the reasons for stress criticality described in Section 7 of this Specification. Therefore, the cri
formed using both information in an Excel file. Intelligent conditional formatting may be u
information to automatically derive the criticality level and highlight the reasons which justify t
below requirement is considered as comprehensive and optimisation may be acceptable
requirements and shall be agreed with COMPANY
LOCATION AND TYPE INFORMATION
UNIT
AREA
PIPE SIZE
LINE NUMBER
FROM
TO
PIPE CLASS
SERVICE
P&ID NUMBER

PROCESS CONDITIONS
1. DESIGN TEMP (°C)
a. Max
b. Min
2. OPERATING TEMP (°C)
a. Max
b. Upset
c. Min
3. DESIGN PRESS (barg)
a. Max
b. Min
4. OPERATING PRESS (barg)
a. Max
b. Min
5. OTHER CONDITIONS
a. Steam Out
b. Fluid Phase (single or two phase)
6. DENSITY

PIPE CONDITIONS
1. DESIGN CODE
2. FLUID CATEGORY
3. PIPE WALL
6. DENSITY

PIPE CONDITIONS
1. DESIGN CODE
2. FLUID CATEGORY
3. PIPE WALL
4. PWHT
5. INSUL TYPE
6. INSUL THK. (mm)
7. FULL VACUUM
8. TEST CONDITION
a. PRESS (barg)
b. MEDIUM

CALCULATION REGISTER
1. ANALYSIS FILE NAME
2. REVISION
3. ORIGNATOR
4. CHECKED
5. APPROVED
6. REMARKS

OVERALL CRTICALITY RATING

1. LEVEL 1: COMPREHENSIVE ANALYSIS
2. LEVEL 2: SIMPLIFIED ANALYSIS
3. LEVEL 3: VISUAL ANALYSIS

ANALYSIS CARRIED OUT

1. STATIC CODE
2. OCCASIONAL
3. BLOW DOWN
4. DYNAMIC Type
5. SURGE / SLUGGING
 NTS
6. FLANGE LEAKAGE
mation contained in the Process Line List and
7. FATIGUE
ication. Therefore, the critical line list shall be
onal formatting may be used to cross relate 8. FEA
he reasons which justify that conclusion. The
ation may be acceptable on project specific
PIPE CRITERIA
1. SEE Table 7.1 Criteria for Flexibility Analysis o
2. NPS >=4 AND PRESSURE RATING >= 900#
3. DESIGN TEMP. < MINUS 30°C AND OPERAT
4. EXOTIC MATERIALS
5. NON-METALLIC
6. TEMP > 427°C
7. D / T > 100

SERVICE CRITERIA
1. PUMPS
2. COMPRESSORS
3. TURBINES
4. BLOWERS
5. LINES TO AND FROM REACTORS AND PRO
6. 4" >= CONNECTED TO AIR COOLERS PLAT
7. OTHER SENSITIVE EQUIPMENT (VESSELS
8. CONNECTED TO EQUIPMENT AND SUBJEC
9. BOILER FEED WATER AND STEAM LIN
GENERATORS
10. WELLHEAD / XMAS TREE

OTHER CRITERIA
1. 2 PHASE FLOW, SURGE, BLOW DOWN LINE
2. SUPERHEATED STEAM
3. VACUUM LINES
4. RELIEF SYSTEMS
5. JACKETED LINES
6. EXPOSED TO FLARE RADIATION

7. TOXIC CATEGORY 'M' SERVICE

8. SEVERE CYCLIC SERVICE
9. SUBJECT TO FATIGUE
10. AIV SERVICE (IN EPC)
11. THERMAL BOWING
Note : Brace / Gussets support requirement for sm
7. TOXIC CATEGORY 'M' SERVICE
8. SEVERE CYCLIC SERVICE
9. SUBJECT TO FATIGUE
10. AIV SERVICE (IN EPC)
11. THERMAL BOWING
Note : Brace / Gussets support requirement for sm
Design Basis AGES-SP-09-001 Appendix A4) s
a for Flexibility Analysis of Piping.
SURE RATING >= 900#
NUS 30°C AND OPERATING TEMP < 5°C
S

M REACTORS AND PROCESSHHEATERS

TO AIR COOLERS PLATED HEAT EXCHANGERS and SHELL AND TUBE)
EQUIPMENT (VESSELS / TANKS)
QUIPMENT AND SUBJECT TO STEAM OUT
ATER AND STEAM LINES TO AND FROM BOILERS AND STEAM

TREE

RGE, BLOW DOWN LINES

EAM

E RADIATION

M' SERVICE
ERVICE
UE
PC)

support requirement for small bore lines in critical service ( as defined in Piping
 M' SERVICE
ERVICE
UE
PC)

support requirement for small bore lines in critical service ( as defined in Piping
P-09-001 Appendix A4) shall be indicated in the Critical line list
 STANDARD CAESAR II SETUP FILE TEMPLATES
Listed below are examples of CAESAR II® ‘CONFIG’ file and ‘SPECIAL EXECU
carefully reviewed in each project.

CAESAR II® SAMPLE ‘CONFIG’ FILE Based on Version 11

EGAMEMORY = 128K

CONNECT_GEOMETRY_THRU_CNODES = YES

MIN_ALLOWED_BEND_ANGLE = 0.5000000E+

MAX_ALLOWED_BEND_ANGLE = 0.9500000E+

BEND_LENGTH_ATTACHMENT_PERCENT = 0.1000000E+

MIN_ANGLE_TO_ADJACENT_BEND_PT = 0.5000000E+

LOOP_CLOSURE_TOLERANCE = 0.1000000E+

THERMAL_BOWING_HORZ_TOLERANCE = 0.1000000E-0

AUTO_NODE_NUMBER_INCREMENT= 0.1000000E+

Z_AXIS_UP= NO

USE_PRESSURE_STIFFENING = DEFAULT

ALPHA_TOLERANCE = 0.5000000E-0

RESLD-FORCE = NO

HGR_DEF_RESWGT_STIF = 0.1000000E+

DECOMP_SNG_TOL = 0.1000000E+

BEND_AXIAL_SHAPE = YES

FRICT_STIF = 0.1000000E+

FRICT_NORM_FORCE_VAR = 0.1500000E+

COMPUTER MODELLING
General Requirements for Computer Software
The software used shall be the CAESAR II® Version applying the contractually a
ASME B31.1 and / or ASME B31.3, and other codes / standards as applicable.

CAESAR II® Set-up file

At the start of each project standardised CAESAR II® config and units’
with COMPANY. These files shall be used for all stress analysis files on that proj
modified unless approved by the COMPANY.

Confirmation the standard ‘config’ file was used shall be included in the stress
analysis with confirmation included in the overall stress report.

Refer to APPENDIX A2 for a sample of Standard CAESAR II® Config file based o
reference
TEMPLATES
and ‘SPECIAL EXECUTION’ settings. These should be
FRICT_ANGLE_VAR =

FRICT_SLIDE_MULT =

d on Version 11
ROD_TOLERANCE =

128K 10
ROD_INC =

= YES 34 1.
INCORE_NUMERICAL_CHECK =

0.5000000E+01 36
OUTCORE_NUMERICAL_CHECK =

0.9500000E+02 37
DEFAULT_TRANS_RESTRAINT_STIF

= 0.1000000E+01 38
DEFAULT_ROT_RESTRAINT_STIFF=

0.5000000E+01 39
IGNORE_SPRING_HANGER_STIFFNE

0.1000000E+01 42
MISSING_MASS_ZPA =

= 0.1000000E-03 92
MIN_WALL_MILL_TOLERANCE =

0.1000000E+02 109
WRC-107_VERSION =

NO 129 1.
WRC-107_INTERPOLATION =

DEFAULT 65 2.
DEFAULT_AMBIENT_TEMPERATURE

0.5000000E-01 33
BOURDON_PRESSURE=

NO 44 0.
COEFFICIENT_OF_FRICTION_(MU) =

0.1000000E+13 49
INCLUDE_SPRG_STIF_IN_HGR_OPE

0.1000000E+11 50
INCLUDE_INSULATION_IN_HYDROT

YES 51 1.
REDUCED_INTERSECTION =

0.1000000E+07 45
USE_WRC329

0.1500000E+00 47
NO_REDUCED_SIF_FOR_RFT_AND_

B31.1_REDUCED_Z_FIX =
lying the contractually agreed revision of
ndards as applicable.

II® config and units’ files shall be set up, approved

nalysis files on that project and must not be

e included in the stress checking of each

R II® Config file based on 2019 version for

 CLAS
E_VAR = 0.1500000E+02 48
ALL_
_MULT = 0.1000000E+01 46
ADD
ANCE = 0.1000000E+01 59
ADD
0.2000000E+01 58
OCC
MERICAL_CHECK = NO 60 0.
DEF
UMERICAL_CHECK = NO 61 0.
B31.
ANS_RESTRAINT_STIFF= 0.1000000E+13 98
ALLO
OT_RESTRAINT_STIFF= 0.1000000E+13 99
USE
ING_HANGER_STIFFNESS = NO 100 0.
YIEL
SS_ZPA = EXTRACTED 101 1.
USE
ILL_TOLERANCE = 0.1250000E+02 107
BAS
RSION = MAR_79_1B1 / 2B1 119 3.
EN13
ERPOLATION = LAST_VALUE 120 1.
LIBE
MBIENT_TEMPERATURE= 0.7000000E+02 135
B31.
RESSURE= NONE 136 1.
B31.
T_OF_FRICTION_(MU) = 0.3000000E+00 140
PRE
RG_STIF_IN_HGR_OPE = NO 141 0.
IMPL
SULATION_IN_HYDROTEST = NO 147 0.
IMPL
TERSECTION = B31.1(POST1980) 32 1.
IGNO
9 NO 62 0.
USE
D_SIF_FOR_RFT_AND_WLT NO 53 0.
USE
CED_Z_FIX = YES 54 1.
CLASS_1_BRANCH_FLEX NO 55 0.

ALL_STRESS_CASES_CORRODED = NO 35 0.

ADD_TORSION_IN_SL_STRESS = DEFAULT 66 2.

ADD_F / A_IN_STRESS = DEFAULT 67 2.

OCCASIONAL_LOAD_FACTOR = 0.0000000E+00 41

DEFAULT_CODE = B31.3 43 3.

B31.3_SUS_CASE_SIF_FACTOR = 0.0000000E+00 40

ALLOW_USERS_BEND_SIF = NO 52 1.

USE_SCHNEIDER NO 63 0.

YIELD_CRITERION_STRESS = MAX_3D_SHEAR 108 0.

USE_PD / 4T NO 64 0.

BASE_HOOP_STRESS_ON_? = ID 57 0.

EN13480_USE_IN_OUTPLANE_SIFS= NO 133 0.

LIBERAL_EXPANSION_ALLOWABLE= NO 137 0.

B31.3_SEC_319.2.3C_SAXIAL= Default 146 3.

B31.3_WELDING / CONTOUR_TEE_ISB16.9 FALSE 139 0.

PRESSURE_VARIATION_IN_EXP_CASE= DEFAULT 143 2.

IMPLEMENT_B313_APP-P NO 144 0.

IMPLEMENT_B313_CODE_CASE_178 YES 145 1.

IGNORE_B31.1 / B31.3_Wc_FACTOR= YES 148 1.

USE_FRP_SIF = YES 110 1.

USE_FRP_FLEX = YES 111 1.

 55 0. BS_7159_Pressure_Stiffening= Des

35 0. FRP_Property_Data_File= CAE

66 2. FRP_Emod_(axial) = 0.32

67 2. FRP_Ratio_Gmod / Emod_(axial) = 0.25

E+00 41 FRP_Ea / Eh*Vh / a = 0.1

43 3. FRP_Laminate_Type = THR

E+00 40 FRP_Alpha = 0.12

52 1. FRP_Density = 0.6

63 0. EXCLUDE_f2_FROM_UKOOA_BENDING = NO

HEAR 108 0. INTRO_EXIT_SCREENS ON

64 0. YES / NO / ARE_YOU_SURE_PROMPTS ON

57 0. OUTPUT_REPORTS_BY_LOAD_CASE YES

133 0. DISPLACEMENT_NODAL_SORTING YES

137 0. DYNAMIC_INPUT_EXAMPLE_TEXT MAX

146 3. TIME_HIST_ANIMATE YES

139 0. OUTPUT_TABLE_OF_CONTENTS ON

143 2. INPUT_FUNCTION_KEYS_DISPLAYED YES

144 0. ENABLE_AUTOSAVE YES

145 1. AUTOSAVE_TIME_INTERVAL 0.30

148 1. PROMPTED_AUTOSAVE YES

110 1. DISABLE_UNDO / REDO NO

111 1. STRCT_DBASE= AISC

 Design_Strain 121 1.

CAESAR.FRP 122 1. VALVE_and_FLANGE=

0.3200000E+07 113 EXPANSION_JT_DBASE=

= 0.2500000E+00 114 PIPING_SIZE_SPECIFICA

0.1527300E+00 115 DEFAULT_SPRING_HANG

THREE 116 3. SYSTEM_DIRECTORY_N

0.1200000E+02 117 UNITS_FILE_NAME=

0.6000000E-01 118 ENABLE_ODBC_OUTPUT

ENDING = NO 134 0. APPEND_RERUNS=

ON 85 1. LOADCASE_TEMPLATE=

OMPTS ON 86 1. Valve / Flange_Dbase_File

CASE YES 87 1. User_Material_File_Name=

ING YES 89 1. ODBC_DATABASE_NAME

XT MAX 94 0.

YES 104 1.

S ON 105 1.

LAYED YES 106 1.

YES 130 1.

0.3000000E+02 131

YES 132 1.

NO 128 0.

AISC89.BIN 70 1.
ALVE_and_FLANGE= CADWORX.VHD 90 1.

XPANSION_JT_DBASE= FLEXPATH.JHD 91 1.

IPING_SIZE_SPECIFICATION ANSI 88 1.

EFAULT_SPRING_HANGER_TABLE= 0.1600000E+02 112

YSTEM_DIRECTORY_NAME= SYSTEM 123 1.

NITS_FILE_NAME= USER.FIL 124 0.

NABLE_ODBC_OUTPUT= NO 125 0.

PPEND_RERUNS= NO 126 0.

OADCASE_TEMPLATE= LOAD.TPL 142 1.

alve / Flange_Dbase_File_Location= CAESARII / CWX 149 2.

ser_Material_File_Name= UMAT1.UMD 150 1.

DBC_DATABASE_NAME= <none> 127 0.

8.3

TYPICAL LOAD CASES

A5.1. Definition of Terms

T1  Maximum design temperature for the pipe.
T2  Operating temperature for the pipe.
T3  Minimum design temperature for the pipe.
P1  Design pressure for the pipe.
W  Pipe dead weight, including operating fluid weight and insulation weight
WW  Pipe dead weight, including full of water and insulation weight, if appli
WIN1  Wind load in North-South direction.
WIN2  Wind load in East-West direction.
U1  Seismic load in North-South direction.
U2  Seismic load in North-South direction.
D  Displacement vector for the corresponding direction
Note :
1) Additional Maximum Operating Temperature (T4) may be introduced to
etc. in line with this specification if applicable. Load cases shall be updated a
2) Whenever spring supports are used for liquid lines at equipment nozzles (Ta
(weight with No liquid) has to be run.

A5.2. Typical Load Case Combinations for CAESAR-II Stress Analysis

The below are minimum Load cases required, the CONTRACTOR shall establ
cases based on the Process / Operation scenario
L1 = T1 + W + P1 (OPE at max design temp)
L2 = T2 + W + P1 (OPE at oper temp)
L3 = T3 + W + P1 (OPE at min design temp)
L4 = W + P1 (SUS at design press)
Stress Comparison of Load Case L4 ≤ Sh (Sh in accordance with ASM

L5 = WW + Hydro Test Pressure (Hydro Test case)

L6 = T2 + W + P1 + WIN1
L7 = T2 + W + P1 – WIN1
L8 = T2 + W + P1 + WIN2
L9 = T2 + W + P1 – WIN2
 Stress Comparison of Load Case L4 ≤ Sh (Sh in accordance with ASM

L5 = WW + Hydro Test Pressure (Hydro Test case)

L6 = T2 + W + P1 + WIN1
L7 = T2 + W + P1 – WIN1
L8 = T2 + W + P1 + WIN2
L9 = T2 + W + P1 – WIN2
L10 = T2 + W + P1 + U1
L11 = T2 + W + P1 - U1

AGES-SP-09-004

Support Loads:
Support Loads shall be based on CAESAR-II load cases as below:

A5.3.1 OPE Load Cases

L1 = T1 + W + P1 (OPE at max design temp)
L3 = T3 + W + P1 (OPE at min design temp)
L4 = W + P1 ( SUS at design press)
L5 = WW + Hydro Test Pressure (Hydro Test case)

A5.3.2 OCC Load Cases

L6 = T2 + W + P1 + WIN1 (OPE: wind in +X at oper temp & Des pr)
L7 = T2 + W + P1 – WIN1 (OPE: wind in –X at oper temp & Des pr)
L8 = T2 + W + P1 + WIN2 (OPE: wind in +Z at oper temp & Des pr)
L9 = T2 + W + P1 – WIN2 (OPE: wind in –Z at oper temp & Des pr)
L10 = T2 + W + P1 + U1 (OPE: seismic in +X at oper temp & Des pr w
L11 = T2 + W + P1 - U1 (OPE: seismic in -X at oper temp & Des pr w
L12 = T2 + W + P1 + U2 (OPE: seismic in +Z at oper temp & Des pr w
L13 = T2 + W + P1 - U2 (OPE: seismic in -Z at oper temp & Des pr wi

A5.3.3 Sway Load Cases

L14 = T2 + W + P1 + D (OPE: oper temp & Des pr, with +X sway)
L15 = T2 + W + P1 – D (OPE: oper temp & Des pr, with –X sway)

L16 = T2 + W + P1 + D
L17 = T2 + W + P1 – D
(OPE: oper temp & Des pr, with +Z sway)
(OPE: oper temp & Des pr, with –Z sway)
 L16 = T2 + W + P1 + D
L17 = T2 + W + P1 – D
(OPE: oper temp & Des pr, with +Z sway)
(OPE: oper temp & Des pr, with –Z sway)
Standard Load cases
Load cases shall be defined so as to show all possible combinations of operating, sustained, thermal
and occasional load cases. It is the CONTRACTOR’s responsibility that these load cases reflect all
possible scenarios of operation. These load cases shall be proposed by the CONTRACTOR,
according to conditions of each individual case, and submitted to COMPANY for discussion, review
and approval. Stresses, loads on supports and displacements shall be reviewed in their relevant load
cases so to be within permissible limits.

The basic load cases are described in APPENDIX A5

TYPICAL LOAD CASES

A5.1. Definition of Terms

T1  Maximum design temperature for the pipe.
T2  Operating temperature for the pipe.
T3  Minimum design temperature for the pipe.
P1  Design pressure for the pipe.
W  Pipe dead weight, including operating fluid weight and insulation weight, if applica
WW  Pipe dead weight, including full of water and insulation weight, if applicable.
WIN1  Wind load in North-South direction.
WIN2  Wind load in East-West direction.
U1  Seismic load in North-South direction.
U2  Seismic load in North-South direction.
D  Displacement vector for the corresponding direction
Note :
1) Additional Maximum Operating Temperature (T4) may be introduced to qualify equ
etc. in line with this specification if applicable. Load cases shall be updated accordingly
2) Whenever spring supports are used for liquid lines at equipment nozzles (Tanks pumps
(weight with No liquid) has to be run.

A5.2. Typical Load Case Combinations for CAESAR-II Stress Analysis

The below are minimum Load cases required, the CONTRACTOR shall establish the add
cases based on the Process / Operation scenario
L1 = T1 + W + P1 (OPE at max design temp)
L2 = T2 + W + P1 (OPE at oper temp)
L3 = T3 + W + P1 (OPE at min design temp)
L4 = W + P1 (SUS at design press)
Stress Comparison of Load Case L4 ≤ Sh (Sh in accordance with ASME B 31.3)

L5 = WW + Hydro Test Pressure (Hydro Test case)

L6 = T2 + W + P1 + WIN1
L7 = T2 + W + P1 – WIN1
L8 = T2 + W + P1 + WIN2
L9 = T2 + W + P1 – WIN2
 Stress Comparison of Load Case L4 ≤ Sh (Sh in accordance with ASME B 31.3)

L5 = WW + Hydro Test Pressure (Hydro Test case)

L6 = T2 + W + P1 + WIN1
L7 = T2 + W + P1 – WIN1
L8 = T2 + W + P1 + WIN2
L9 = T2 + W + P1 – WIN2
L10 = T2 + W + P1 + U1
L11 = T2 + W + P1 - U1

AGES-SP-09-004

Support Loads:
Support Loads shall be based on CAESAR-II load cases as below:

A5.3.1 OPE Load Cases

L1 = T1 + W + P1 (OPE at max design temp)
L3 = T3 + W + P1 (OPE at min design temp)
L4 = W + P1 ( SUS at design press)
L5 = WW + Hydro Test Pressure (Hydro Test case)

A5.3.2 OCC Load Cases

L6 = T2 + W + P1 + WIN1 (OPE: wind in +X at oper temp & Des pr)
L7 = T2 + W + P1 – WIN1 (OPE: wind in –X at oper temp & Des pr)
L8 = T2 + W + P1 + WIN2 (OPE: wind in +Z at oper temp & Des pr)
L9 = T2 + W + P1 – WIN2 (OPE: wind in –Z at oper temp & Des pr)
L10 = T2 + W + P1 + U1 (OPE: seismic in +X at oper temp & Des pr with friction
L11 = T2 + W + P1 - U1 (OPE: seismic in -X at oper temp & Des pr with friction
L12 = T2 + W + P1 + U2 (OPE: seismic in +Z at oper temp & Des pr with friction
L13 = T2 + W + P1 - U2 (OPE: seismic in -Z at oper temp & Des pr with friction

A5.3.3 Sway Load Cases

L14 = T2 + W + P1 + D (OPE: oper temp & Des pr, with +X sway)
L15 = T2 + W + P1 – D (OPE: oper temp & Des pr, with –X sway)

L16 = T2 + W + P1 + D
L17 = T2 + W + P1 – D
(OPE: oper temp & Des pr, with +Z sway)
(OPE: oper temp & Des pr, with –Z sway)
 L16 = T2 + W + P1 + D
L17 = T2 + W + P1 – D
(OPE: oper temp & Des pr, with +Z sway)
(OPE: oper temp & Des pr, with –Z sway)
 L12= T2 + W + P1 + U2 (OPE: seismic in +Z at oper temp & Des pr with frict
L13= T2 + W + P1 - U2 (OPE: seismic in -Z at oper temp & Des pr with fricti
L14 = T2 + W + P1 + D (OPE: oper temp & Des pr, with +X sway)
L15 = T2 + W + P1 – D (OPE: oper temp & Des pr, with –X sway)
L16 = T2 + W + P1 + D (OPE: oper temp & Des pr, with +Z sway)
L17 = T2 + W + P1 – D (OPE: oper temp & Des pr, with –Z sway)
L18 = L6 – L2 (OCC: +X wind only, algebraic combination method
L19 = L7 – L2 (OCC: –X wind only, algebraic combination method)
L20 = L8 – L2 (OCC: +Z wind only, algebraic combination method)
L21 = L9 – L2 (OCC: –Z wind only, algebraic combination method)
L22 = L10 – L2 (OCC: +X seismic only, algebraic combination meth
L23 = L11 – L2 (OCC: –X seismic only, algebraic combination meth
L24 = L12 – L2 (OCC: +Z seismic only, algebraic combination meth
L25 = L13 – L2 (OCC: –Z seismic only, algebraic combination meth
L26 = L18 + L4 (OCC: +X wind with Weight & Des press for Primary
scalar combination method)
L27 = L19 + L4 (OCC: –X wind with Weight & Des press for Primary
scalar combination method)
L28 = L20 + L4 (OCC: +Z wind with Weight & Des press for Primary
scalar combination method)
L29 = L21 + L4 (OCC: –Z wind with Weight & Des press for Primary
scalar combination method)
L30 = L22 + L4 (OCC: +X seismic with Weight & Des press for P
check, scalar combination method)
nozzle loads, (OCC: –X seismic with Weight & Des press for P
L31 = L23 + L4
check, scalar combination method)
itional WNC
L32 = L24 + L4 (OCC: +Z seismic with Weight & Des press for P
check, scalar combination method)
L33 = L25 + L4 (OCC: –Z seismic with Weight & Des press for P
check, scalar combination method)
quired load
Stress Comparison of Load Case L26, L27, L28, L29, L30, L31, L32, L33
accordance with ASME B 31.3)

L34 = L1 – L4

L35 = L2 – L4

L36 = L3 – L4 (EXP: Stress range between min design Temp & insta
combination method)
AGES-SP-09-004
L37 = L1 – L3 (EXP: stress range between max design temp & min desi
combination method; for secondary thermal stress range ch
Stress Comparison of Load Case L34, L35, L36, L37 ≤ f [(1.25 Sc+0.25Sh)]
(f, Sc, Sh, SL in accordance with ASME B 31.3)
 L36 = L3 – L4 (EXP: Stress range between min design Temp & insta
combination method)
AGES-SP-09-004
L37 = L1 – L3 (EXP: stress range between max design temp & min desi
combination method; for secondary thermal stress range ch
Stress Comparison of Load Case L34, L35, L36, L37 ≤ f [(1.25 Sc+0.25Sh)]
(f, Sc, Sh, SL in accordance with ASME B 31.3)

L38 = L14 – L2 (OCC: +X sway for Secondary stress check, algebraic comb
L39 = L15 – L2 (OCC: –X sway for Secondary stress check, algebraic comb
L40 = L16 – L2 (OCC: +Z sway for Secondary stress check, algebraic comb
L41 = L17 – L2 (OCC: –Z sway for Secondary stress check, algebraic comb
Stress Comparison of Load Case L38, L39, L40, L41 ≤ 3 Sc

When using ASCE 7-16 for seismic load calculations, the related load combinatio
updated in accordance with the respective code provisions to include Vertical seism

r zero)
zero)
r zero)
zero)
er temp & Des pr with friction multiplier zero)
r temp & Des pr with friction multiplier zero)
, with +X sway)
, with –X sway)
, with +Z sway)
, with –Z sway)
raic combination method)
raic combination method)
raic combination method)
raic combination method)
gebraic combination method)
gebraic combination method)
gebraic combination method)
gebraic combination method)
t & Des press for Primary code stress check,
d)
t & Des press for Primary code stress check,
d)
t & Des press for Primary code stress check,
d)
t & Des press for Primary code stress check,
d)
Weight & Des press for Primary code stress
method)
Weight & Des press for Primary code stress
method)
eight & Des press for Primary code stress
method)
eight & Des press for Primary code stress
method)
29, L30, L31, L32, L33 ≤ 1.33 Sh (Sh in

in design Temp & install Temp; algebraic

design temp & min design Temp; algebraic

y thermal stress range check.)
f [(1.25 Sc+0.25Sh)]
 in design Temp & install Temp; algebraic

design temp & min design Temp; algebraic

y thermal stress range check.)
f [(1.25 Sc+0.25Sh)]

ess check, algebraic combination method)

ess check, algebraic combination method)
ss check, algebraic combination method)
ss check, algebraic combination method)
3 Sc

e related load combinations shall be suitably

s to include Vertical seismic loads
14
BROWNFIELD WORKS & TIE-INS
General
Piping stress analysis shall account for the stresses, displacements and pipe support locations of
existing lines and determine how flexibility can be provided for new piping.

Tie-ins
The stress engineer shall participate in design discussions to determine the location of tie-ins to
existing lines.

Tie-in locations close to equipment nozzles shall be avoided.

Wherever feasible, a tie-in to an existing header shall be located close to an existing axial stop to
minimise the displacements imposed on the new pipe.

The extent and scope of modelling of existing piping integrated with new pipe system shall be up to
the nearest stress isolation boundary like axial stop / anchor and the same shall be agreed with
COMPANY.

The CONTRACTOR shall ensure, stress analysis of tie-in or modified existing piping complies with all
ASME B31.3 code requirements and that load, deflection and other criteria meet the requirements of
this specification.

The stress analysis of the existing sections of the tie-in arrangement shall take into consideration the
version of ASME B31.3 applicable at the time of the original design. Any non-compliance issue with
respect to existing and new system shall be discussed and agreed with the COMPANY

The stress analysis of tie-in piping shall consider the existing pipe stress analysis and asso
stress sketch information, where available. This shall include the following:
a. Piping geometry
b. Pipe support functions and gaps
c. Operational functionality according to assumptions in the stress analysis (for example, no
uncontrolled lift off).
d. Whether the loads and spring rates of existing spring supports require modification.
e. Existing and new springs and other purchased item tag numbers shall be recorded on the new
stress sketch.
f. Tie-in numbers should be identified in the stress model as a “Node name”.
g. If a tie-in location and / or associated piping is included within two different models, stress reports
shall be cross referenced.

Where existing piping or stress analysis details are unavailable the CONTRACTOR shall create a new
CAESAR II analysis file. The new analysis shall accurately model the existing system and support
functionality and suitability for the addition of new lines and the tie-in piping. This will require site
surveys and obtaining of existing wall thicknesses by inspection if not available. The CONTRACTOR
shall ensure all the relevant data on existing lines including any site information related to the stress
analysis of tie-in’s or modifications to existing piping are included in the related stress analysis report
13.3
Stress Analysis of Buried Piping
All buried pressurised metallic piping (6” and above) shall be subject to stress analysis which shall
consider soil parameters as well as process maximum operating and design conditions.

For Buried piping, soil properties, depth of sand bed / soil over the pipes shall be agreed as part of
stress analysis basis, prior to carrying out analysis.

Large cooling water pipes shall be assessed to prevent subsidence.

13.4
Stress Analysis of FRP Piping
The FRP (GRE GRP, etc.) piping VENDOR shall endorse or perform the design and stress analysis
calculations for above and underground non-metallic piping systems in accordance with BS EN ISO
14692 Pt 3 and applicable COMPANY FRP specification

FRP Vendor/ Manufacturer or his qualified and experienced engineering service provider shall carry
out the Stress Analysis of new GRE System by Caesar II software in line with ISO 14692-3, using the
GRE mechanical properties supplied by manufacturer to ensure all forces, loads, moments and
stresses are within allowable stress limits.

The flexibility and stress intensity factors for FRP pipe and fittings shall be as per ISO 14692 Part 3
Annex B.

The stress analysis shall use the allowable stress envelope for non-metallic pipe and fittings together
with pipe span considerations based on FRP Manufacturer data.

Finite element analysis (using a recognized FE package approved by the COMPANY) of non-standard
shapes or critical components as defined by the COMPANY shall be performed to demonstrate fitness
for purpose as requested by the COMPANY

The stress analysis at interfaces between non-metallic / metallic piping materials shall include the
metallic piping system up to the nearest anchor block, limit stop or other fixed points. The minimum
forces and moments shall be maintained at the interface of FRP and Metallic pipes not to have any
adverse effect on FRP part of piping.

FRP piping design and calculation documents shall be submitted for COMPANY review and approval
prior to fabrication and subsequent activities. Refer Appendix A8 for Documents & Information
required for FRP stress analysis

The surge loads and details like location etc. should be provided to the FRP VENDOR by the
CONTRACTOR.

The FRP pipe system shall be evaluated and analysed for adequate flexibility and stress le
accordance with the following;
1. Prevention of thermal expansion or contraction which may cause;
a. Failure of the pipe system or supports from over-stress or fatigue
b. Excessive loads on connected equipment
c. Leakage at joints
d. Excessive stresses or distortion of pipes or valves
e. Disengagement of pipe system from its supports.
2. The following applied loads shall be considered (if applicable);
a. Design conditions, pressure, temperature
b. Loads induced from connected equipment, supports, anchors, guides
c. Dead loads due to pipe weight, valves, service fluid, insulation or other permanent loads
d. Soil and traffic loads on buried pipe systems
e. Hydrostatic test loads
f. Thermal loads
g. Frictional loads
h. Environmental conditions, e.g. wind, seismic
i. Vibrational loads
j. Differential settlement
k. Spring forces due to bellows
l. Pressure relief valve reaction forces
m. Water hammer or pressure surge forces Installation loads, e.g. transportation, erection etc.
3. All stress analysis calculations shall be based on the structural wall thickness only

4. Consideration shall be taken of startup, emergency shut down and any other dynamic loading
situations

5. Consideration shall be taken of the interface with existing plant or lines and the relevant boundary
conditions

6. Consideration shall be taken of the required project design lifetime

7. If the analysis determines that the flexibility of the FRP pipe system is insufficient
a. Optimize/modify anchors, line stops or guides
b. Change in pipe routing
c. Expansion joints shall not be used and if used in utility system with prior approval with
COMPANY after exhausting all options.

In addition to the above requirements, the following shall be considered in the analysis
a. For buried pipe the axial stress analysis shall include (according to AWWA M 45) thermal
expansion/contraction, Poisson’s effect, etc. If coupling joints (i.e. joints that do not transmit axial
loads) are used then the axial loads from frictional resistance should be included
b. For above ground pipe the hoop stress analysis shall include internal pressure, hoop bending
due to hoop deflection and pipe interactions with pipe supports
c. For above ground pipe the axial stress analysis shall include axial bending due to gravity,
environmental loads, thermal loads, Poisson effect due to internal pressure and internal pressure
induced effects at fittings
d. The axial pipe stress between anchors associated with axial forces due to Poisson effect due to
internal pressure, thermal expansion/contraction loads. Also the interaction between the pipe and
supports shall also be considered
Stress Analysis of Flare and Relief System
Flare lines are often subject to AIV therefore require higher wall thickness, which shall be considered
during analysis based on AIV studies and EI Guidelines.
Piping exposed to flare radiation: stress analysis accounts for the increase in temperature of the pipin
system due to flare radiation.
The pipe support arrangement for flare system piping, shall consider the presence of liquid in
accordance with Table 13.1. However if these are hydro tested then the additional requirements state
in Section 9.5 shall be followed.
Note: The requirements in Table 13.1 are intended to calculate pipe support loads for structural desig
and to verify acceptability of the mid-span longitudinal stress.