Welcome to COP

PIPE STRESS ANALYSIS IN PROCESS INDUSTRIES

Prepared by :
Hitesh N Prajapati (PP)
Hitendrakumar B Patel (PP)
Anoop Agrawal (EQ)

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 Objective of PIPE STRESS ANALYSIS

 Objective of Pipe Stress Analysis is ….

To ensure Safety Against Failure of the Piping System by

verifying structural integrity against the loading
conditions, both external and internal, expected to occur
during the life cycle of the system in the Plant.

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STRESS ANALYSIS

 Static Analysis

 Dynamic Analysis ( Slug Flow )

 Seismic Analysis (Pseudo-Static & Response Spectrum )

 Composite Analysis

 Flange Leakage Analysis

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS
 Static Analysis is performed to analyse the piping system
behaviour under static loads like….

Dead & live

Load

Effect of
support and
terminal
movement
Wind load

Thermal
expansion &
Contraction
L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

 Wind Analysis …..

 Wind Analysis criteria
 Calculation of wind pressure as per IS 875, BS 6399,
Project Spec
User defined Elevation Vs Wind pressure profile
Combination of Static and Wind load

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

Static load
 Relief Valve Analysis ….. (operating
condition) +
Reaction
 Reaction force of PSV is force of
Valve
combined with Operating
condition of line.
 Static Load + Reaction force
(OPE)
 Sustained Stress + stress
Application of
due to Reaction force Reaction force-
(Occasional Stress Check) Closed system

 Reaction force is multiplied

by factor 2 for open to Atm.
PSV release as per API RP 520

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

 Seismic load combined with Static Load ( Pseudo-Static

Method…..
Seismic force is combined
with Operating condition of Static load
line. (operating
condition) +
Seismic Force
Static Load + Seismic
Force (OPE)
Sustained Stress + stress
due to Seismic force
( Occasional Stress Check)

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 DYNAMIC ANALYSIS contd…

 Dynamic Analysis is performed to analyse effect of Two-

phase flow ( Slug force )

Total Straight Length

Axial Force
Vapour Component
length Slug length

Slug Periodicity

Slug Periodicity
Slug Vapour Slug
Force

Elbow Node

Resultant Slug
Orthogonal Force Force
component
Time
L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 DYNAMIC ANALYSIS
 Dynamic Analysis is performed to analyse effect of Two-
phase flow ( Slug force )
 Process data sheet for two-phase flow

 Calculation of Slug force

 Generating force spectrum for each elbow based on slug
force and duration of slug impact on elbow
 Static loads are combined with dynamic load

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 DYNAMIC ANALYSIS
 Spectrum generation ( Time Vs Force )

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 SEISMIC ANALYSIS
 Criteria of Seismic Analysis ( DHDT project )
 All emergency service lines of diameter 8” and above (e.g.
Fire water line)
All two phase flow lines of diameter 12” and above.
 All lines with 900# and higher-pressure class of diameter
16” and above.
For those lines not coming under the above criteria shall be
selected for seismic analysis as per the following criteria.
1.Elevation above >= 35.0 m and diameter > 16”.
2.All lines 36” and above for any elevation.

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 SEISMIC ANALYSIS

Response Spectrum method is used for Seismic Analysis.

Site Specific response spectra “Frequency Vs Seismic

Acceleration” is obtained from client with critical damping of
2%.

Combining the maximum response of different modes at

each node by SRSS ( Square root of sum of squares).

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 SEISMIC ANALYSIS
 Analysis by using CAESAR II.
At the outset Static Analysis is performed.
 Seismic Force is combined with sustained stress of
operating temperature and evaluated against Occasional
Stress for code compliance.
Seismic force are combined with operating load for
checking of equipment nozzles loading during seismic case.

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 SEISMIC ANALYSIS
 Seismic Analysis by CAESAR II

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 COMPOSITE ANALYSIS
 Composite Analysis Criteria….
 Integrated composite analysis is carried out for lines
which are highly critical and significant interaction with
equipments, technical structure and auxiliary supporting
structure, by taking care of stiffness of equipments and
structure.
 Requirements of Composite Analysis is specified by
Clients e.g. Heater Transfer Line, Column Overhead Lines,
Column Overhead lines to AFC, Reactor lines.
 Composite Analysis is performed in CAESAR II by
modeling Piping , Equipments, Structure and auxiliary
supporting structure.

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 COMPOSITE ANALYSIS
 Highlights of Composite Analysis….
 Exact simulation of Equipments and Structure.
 Effects of Equipment movement and Structure is taken
care.
 Actual structure stiffness is considered.
 Highly complex and time consuming.
 Piping behaviour is considered along with equipments and
structure

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 COMPOSITE ANALYSIS
 Highlights of Composite Analysis….

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 FLANGE LEAKAGE ANALYSIS
 Criteria for Flange Leakage Analysis.
 Flange rating 900# and above.
 PSV inlet / oulet flanges.
 Flanges of Line for Hydrogen services.

 Flange Leakage Analysis

 Equivalent pressure check
 Gasket seating stress
50% of bolt yield strength
Flange Strength ( Yield strength )

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 FLANGE LEAKAGE

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 FLANGE LEAKAGE ANALYSIS


L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

 Wind Analysis criteria in general …..

 Column overhead line

 Heater Transfer line
 Flare Header
 Outside diameter (including insulation thickness)
of line 20” and above and elevation of line above10
meter from HPP.

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

Y
 User Defined Wind Profile

Z X

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

 Combination of Static + Wind load for Analysis run.

Static Stress induced by

load(operating windload check
condition) against occassional
+Wind load stress

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

 Calculation of wind pressure based on BS6399

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 DYNAMIC ANALYSIS
 Process Input data sheet of Two-phase flow for each
line…

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 DYNAMIC ANALYSIS
 Calculation of Slug force at each elbow

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 DYNAMIC ANALYSIS
 Spectrum generation ( Time Vs Force )

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED
 STATIC ANALYSIS contd…

 Slug Flow analysis – Backer Chart

L&T-CHIYODA
LARSEN & TOUBRO
LIMITED LIMITED