Page 1 of 15

HINDUSTAN PETROLEUM CORPORATION LTD

MUMBAI REFINERY

DHT PROJECT- HGU UNIT


LEPCC
PART : III
SECTION : A


TITLE: STRESS DESIGN BASIS





DOCUMENT NO: 44LK-5100-00/L.02/0003/A4















1 17.12.08 12 Revised & issued for
HGU feed
DRP RMP PVS
0 4.10.08 12 Approved by HPCL and
issued for implementation
DRP RMP PVS
A 12.02.08 12 Issued for Information DRP RMP PVS
Rev No. Issue Date Pages Description
Prepared
By
Checked
By
Approved
By
Jacobs
HPCL, Mumbai Stress Design Basis Part - III
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44LK 5100

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TABLE OF CONTENTS




1.0 PURPOSE


2.0 SCOPE


3.0 DEFINITIONS


4.0 SELECTION


5.0 RELATED DOCUMENTATION


6.0 PIPE STRESS ANALYSIS AND SUPPORTING


7.0 CODES AND STANDARDS


8.0 SOFTWARE USED


9.0 DOCUMENT REQUIRED


10.0 ATTACHMENTS


10.1 CRITERIA FOR IDENTIFYING CRITICAL LINES


10.2 CATEGORISATION FOR SEISMIC ANALYSIS















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1.0 PURPOSE
This design basis deals with the subject of Identification of Stress Critical pipelines and
preparation of Critical line list. This procedure also defines the minimum requirements for
performing stress analysis, design and location of spring, support and extent of system
analysis with the extent of documentation required for flexibility analysis
Purpose of piping stress analysis is to ensure:
Safety of piping and piping components
Safety of connected equipment and supporting structure
Piping deflections are within the limits

2.0 SCOPE
This specification covers the supply of engineering services to perform a complete piping and
pipe support analysis for new and modified piping systems for HPCL Mumbai Refinery for its
DHT Project.

3.0 DEFINITIONS
3.1 CRITICAL LINES / CRITICAL LINE LIST
Critical lines or Critical Line List as referred to in this procedure relates to Piping Stress
Critical Lines and does not include or refer to process critical lines.
3.2 STRESS ANALYSIS TEMPERATURE


Stress Analysis Temperature refers to either Maximum Operating Temperature or Steam-
out temperature / hot Nitrogen purging temperature of the lines under review whichever is
higher. In absence of the above values, it refers to the Design Temperature of the line under
review. The Line List should be strictly followed in obtaining the above temperature
3.3 DESIGN PRESSURE
Design Pressure refers to the Design Pressure of the line under review as indicated on the
Line List. Design Pressure is as defined in clause 301.2 of ASME B 31.3.
3.4 TEMPERATURE FOR FLEXIBILITY ANALYSIS
The temperature to be used for the flexibility analysis shall be taken as the maximum /
minimum temperature which the pipe will see under any combination of different normal /
abnormal operating conditions, as defined in clause 301.3 of ASME B 31.3. Where piping is
exposed to direct sunlight, solar radiation temperature of 70
0
C is considered in establishing
the maximum temperature of piping. Even, for non-critical piping exposed to direct sunlight on
pipe rack or elsewhere, expansion loops, wherever essential, are provided to take care of
pipe movements resulting from piping skin temperature due to solar radiation.
In general, unless there is a difference of more than 50
0
C between working temperature and
the design temperature, the design temperature should be taken as Flexibility temperature.If
the difference is higher than 50
0
C the stress analysis temperature is needed to be decided in
consultation with process Licensor/Group.
The temperature under Fire Condition are not considered for stress analysis except for flare
lines.

Ambient Temperature shall be considered as 21
0
C. the assumed piping installation
temperature. The displacement stress range from this installation temperature to the
minimum recorded ambient temperature of 12
0
C being less than the same from installation
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temperature to the maximum operating temperature of hot piping in most cases the later
governs as per clause 319.2.3 of ASME B 31.3.

4.0 METHOD OF ANALYSIS
A line is selected and listed as a Critical Line provided it falls under any one of the categories
defined in Attachment 10.1 and is intended to include the special requirements of Piping
Stress Engineer. It is hence defined as any line for which a flexibility review is required or
where pipe supporting is deemed to be critical and needs review by a Stress
Engineer.Hence all lines following outside the categorization are deemed non critical which
can be reviewed using nomographs manual calculation and/on visual analysis.
All lines in this list essentially need a formal computer analysis with a trunion
calculation,Flange leakage calculation and nozzle load calculation as required,Very large
diameter (thin walled)pipes and ducts need special design consideration which should be
highlighted.

4.1 LINES DEEMED TO BE SUPPORT CRITICAL
Lines subjected to two-phase flow
Cross country pipelines.
Lines with pipe thickness Sch 160 or greater
Lines DN 400 and above with pipe thickness less than 8 mm.
Lines DN 250 and above with corrosion allowance 3 mm and above
Lines with high concentrated loads such as heavy valves or fittings etc.

Lines downstream of Relief Valve / letdown Control Valves / bursting (rupture) discs.
connecting to vent or flare systems or discharging to atmosphere.

Liquid Blow down Lines

Lined pipes
Non-metallic pipes
4.2 LINES NEEDING DYNAMIC ANALYSIS
There are instances where in the frequency of the applied load is comparable to the natural
frequency of the piping system. Such systems tend to store the energy and release it
according to certain scientific laws. Such a system is dynamic in nature and the study of the
response of such a system is referred to as Dynamic Analysis. Examples of such kind of
systems are Relief Valve discharge lines, Safety valves / rupture discs, water hammer and
surge in pipelines, two phase slug flow in pipelines, reciprocating pumps and compressor
piping, submarine piping,pipelines subjected to earthquake of large magnitude etc.
4.3 SPECIAL PIPING
Special piping forming part of reformer tubes, heater internal piping, etc. are treated as
proprietary piping and nozzle loading at the Interface connections are to be co-ordinated with
vendor.

4.4 Pipelines which will require seismic analysis,Refer to Attachment 10.2
5.0
RELATED DOCUMENTATION
5.1 CRITICAL LINE LIST FORMAT.
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The critical line list shall be prepared from the project line list document by inserting following
relevant fields such as
Stress category Critical (C) or Non-critical (NC), stress package no., stress analysis
temperature, support critical nature of the line, dynamic loadings, steam out / purge
temperature etc.
The list shall reflect analysis status of line that includes its input received date from design &
output handover date to design and specific remark if any.
5.2 LINES AFFECTING THE FLEXIBILITY OF CRITICAL LINES
a) Non-critical Lines found to affect the flexibility of critical lines which have not been
included during the initial review are subsequently added to the Critical Line List.
b) Non-critical Lines on which advice may be sought by the Lead Piping Engineer are not
normally entered into the Critical Line List but covered verbally, or by a memorandum if a
record is required.
c) All non critical lines (having size more than half of main run size) that tie into critical lines
should be considered as critical upto first anchor if they have significant effect on main
line flexibility.

6.0 PIPE STRESS ANALYSES AND SUPPORTING
6.1 Piping support Criteria and General Guidelines :
Piping system shall be properly supported taking in to account of the following points:
a. Sustained Loads:
Weight of piping (Bare pipe, service fluid, valves, flanges etc.)
Weight of insulation (if any)
Weight of online equipment (if any)
Weight of instruments (if any)
Pressure relief load due to safety valve operation
Wind / Seismic loads (as and when required)
Dynamic loads due to pulsating flow/two phase with slug flow
Pressure-Thrust loads in case of expansion joints.
b. Thermal Loads
Thermal loads due to operating / design / steam out / decoking or any other abnormal
condition.
Pipe supporting shall be preferably follow the basic span as given in Piping Design Basis
(Annexure D), except for flare line in offsite on trestles in which case the basic span shall
be restricted to max.18m. For sizes not covered in Piping Design Basis, basic span shall
be established based on project requirement. For piping on rack or sleeper, as a
minimum, providing resting support on every grid of pipe rack / sleepers mandatory.
Guides shall be provided on straight run of pipes at intervals as specified in piping design
basis (Annexure C), unless specifically becomes non-viable due to flexibility problems.



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Additional supports, guides, anchors, special supports like spring supports and sway
braces shall be provided based on detailed analysis of piping system to restrict the forces
on nozzles of critical equipments like pumps, compressors, turbines, exchangers, fin-fan
coolers etc.
A permanent support, either resting or spring support shall be provided for lines which do
not need any supporting otherwise but require supporting during maintenance.
Pads will be provided at pipe supports, for all sizes and services of lines irrespective of
whether shoes are required or not.
Adequate care shall be taken for small bore(1 inch NB and below) branch from piping.
For all lines in 600# and above classes - lines having two phase flow and lines having
pulsating flow such as discharge of reciprocating compressors and reciprocating pumps,
all small bore branches (vents, drain, orifice traps, pressure / temperature tapings,
sample connections), PSV / TSV inlets etc., shall be provided with 2 number stiffeners at
90 Deg to each other from main pipe to impart adequate stiffness to the branch
connection. The stiffeners shall be made from 6 mm thick flats of material equivalent to
the pipe material. Irrespective rating, the stiffeners shall be provided for all orifice taps, all
small bore tapings from PSV inlet / outlet lines and all small bore tapings from control
valve manifolds.
For pulsating flow lines, detailed thermal and vibration analysis by analog study shall be
done to decide on location of anchor supports and guides etc.
In case of two phase with slug flow lines, piping design shall be checked by dynamic
analysis to prevent vibrations.
Piping support design shall be such that deflection in piping systems due to sustained
loads shall not exceed 15mm, between two adjacent supports.
Long trunion type of supports (more than 0.5m) is to be avoided. In case long trunion
support is unavoidable, trunion height shall be restricted to 0.5m and balance height to be
made up by providing extended structure.
In case of heaters having the provision for steam-air decoking, the main lines and
decoking lines should not be in hanging position when not in operation.
Piping passing through technological structure or passing near the concrete column etc.
should have adequate space or gap considering insulation, to avoid restriction of line
movement during thermal expansion.
High density PUF block shall be considered for cold piping supports. Wooden blocks may
be used for load taking supports on vertical lines or as anchor supports.
All pipe supports shall be so designed that there is no undue tension on equipment
flanges.
6.2 Flexibility Analysis Criteria and General Guidelines:
6.2.1 Piping stress analysis shall follow ASME B31.3 and shall complete to prevent over stressing
of pipe during operating conditions with wind and seismic loadings. During sustained,
occasional (wind and seismic) & thermal expansion loading on piping, the material allowable
stresses shall be as per ASME B 31.3 for ASTM materials. For DIN material specifications
the allowable stress values shall be calculated as per ASME B 31.3 clause 302.3.2(d),
wherein yield strength and ultimate strength values at temperature shall be taken from DIN
material standards. For DIN material specifications, the other material properties viz. elastic
modulus, density, coefficient of thermal expansion shall be taken from the respective DIN
material standards.
6.2.2 Analysis shall include, but not be limited to the following; thermal, dead weight, internal
pressure, wind and seismic, and a combination of these based on ASME B 31.3.
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6.2.3 At a minimum, two (2) orthogonal horizontal components and a vertical component of ground
motion will be considered in the seismic analysis. The seismic design shall be as per UBC,
seismic zone-3. The minimum seismic accelerations applied to the piping system in the
horizontal and vertical plane shall be 0.3g and 0.15g respectively as per seismic zone-3 of
UBC. Accelerations shall be combined and applied as follows to determine the most
unfavourable condition:
0.7X, 0.7Z, 1.0Y (Y is vertical)
1.0X, 0.3Z, 1.0Y
0.3X, 1.0Z, 1.0Y

Where, X and Z = 0.3 and Y = 0.15
Based on the above combinations, the magnitude and direction of accelerations shall be
applied to the piping system as follows:

X-Direction Z-Direction Y-Direction (Vert.)
0.21g 0.21g 0.15g
0.3g 0.09g 0.15g
0.09g 0.3g 015g

Direction of loading () shall produce the most unfavourable condition.
6.2.4 Wind analysis shall follow ASCE-7 using a basic wind velocity of 160 km/h. At a minimum,
wind loading shall be applied to all components in two (2) perpendicular horizontal directions
at elevation 10 m and above. Shape factor for piping shall be considered as 0.7. ASCE-7
Exposure category C [kz = 0.85 for z <4.6 m & kz= (0.10044* z)^0.2105 for z >= 4.6 m up to
274m] & gust factor of value 1.5 shall be considered for taking care of effect of height and
topography. Wind and seismic loading will not occur simultaneously.
6.2.5 Analysis of all nozzles loading on vessels within the piping boundaries is covered in this
specification. Nozzle analysis shall follow the guidelines of ASME Section VIII, Division 1, and
WRC 297 & 107 (latest editions). Nozzle stresses shall fall within the allowable per
6.2.6 All forces on connections to equipment shall not exceed maximum allowable as specified by
equipment vendor.
6.2.7 Pipe supports loads shall be based on the maximum loads determined by the piping analysis.
JE shall evaluate all pipe support loading including friction forces due to thermal expansion
using good engineering judgement. Adjustments shall be made to the piping system and
model such that the pipe supports loads are within a reasonable uniformity throughout the
piping system.
6.2.8

Various Load cases built in Caesar II to check stress in piping system are listed below.




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Load Case Type Remarks

1) WW+HP HYD
2) W+T1+P1 OPE
3) W+T2+P1 OPE
4) W+T1+P1+U1 OPE Seismic load (0.21g,0.15g,0.21g)
5) W+T1+P1+U2 OPE Seismic load (0.3g,0.15g,0.09g)
6) W+T1+P1+U3 OPE Seismic load (0.09g,0.15g,0.3g)
7) W+T1+P1-U1 OPE Seismic load (0.21g, 0.15g, 0.21g)
8) W+T1+P1-U2 OPE Seismic load (0.3, 0.15g,0.09g)
9) W+T1+P1-U3 OPE Seismic load (0.09g, 0.15g, 0.3g)
10) W+T1+P1+WIN1 OPE WIN1 +X direct wind load
11) W+T1+P1+WIN3 OPE WIN3 +Z direct wind load
12) W+P1 SUS
13) W+P2 SUS
14) L2-L12 EXP
15) L3-L12 EXP
16) L4-L2 OCC
17) L5-L2 OCC
18) L6-L2 OCC
19) L7-L2 OCC
20) L8-L2 OCC
21) L9-L2 OCC
22) L10-L2 OCC
23) L11-L2 OCC
24) L12+L16 OCC
25) L12+L17 OCC
26) L12+L18 OCC
27) L12+L19 OCC
28) L12+L20 OCC
29) L12+L21 OCC
30) L12+L22 OCC
31) L12+L23 OCC



P1- Maximum Operating Pressure W Dead Weight

T1-Maximum Operating Temperature WW Water Weight

P2-Design Pressure WIN Wind Load

T2-Design Temperature U - Uniform Load

HP- Hydro test Pressure L2 Load Case


SUS, EXP, OCC, HYD, OPE Various load types, viz., sustained, expansion, occasional, hydro test,
operating etc.
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7.0
CODES AND STANDARDS

The following codes and standards shall apply in the design and analysis of the piping
systems covered under this specification:
Allowable Stress ASME B 31.3
Piping ASME B 31.3
Nozzle Loadings As per specifications enclosed in the BID
Wind Analysis ASCE 7 98
8.0 SOFTWARE USED

COADE

s piping stress analysis software Caesar II, Version 5.0 or above shall be used
for Pipe stress analysis. Pipe thickness & material allowable stress values will be
manually fed as input.

9.0 DOCUMENT REQUIREMENT
9.1
A written report shall be submitted on the piping and equipment analysis. The report shall
include all pertinent information that shall include but not be limited to the following :

Location and type of pipe supports with loads and movements.
Location of expansion joints and movements.
Vertical and horizontal loads including moments at all support points.
Vertical and horizontal loads including moments on all equipment and vessel
connections.
Caesar II analysis report, which shall include as a minimum, restraint forces,
movements and stresses for all load cases. For flange connection, loaded with high
bending moments and/or tensile forces in piping or at equipment connections, Caesar
II flange leakage report will be provided. For piping analyzed, if subjected to hydro test,
hydro test load case will be made in Caesar II to check for loading under hydro test &
the requirement of any additional temporary supports for hydro test.
Detailed nodal model used for the stress analysis
All assumptions and limitations applied to the analysis.


9.2 All dimensions and analysis shall be performed using metric and SI units.

9.3 The final report / stress package folder shall be submitted as follows:
1. Front sheet with Approval status
2. Isometrics with Hand written following information.
Node numbers
Type of supports selected by stress engineer
Springs / Bellows data required for procurement like spring rate, loads, tide/untied
information and SM (special material) identification.
Maximum Expansion and sustain stress values with node number
Nozzle/Anchors initial movements and piping imposed forces and moments on
the same


Support loads (anchors, guides or rest) only they are above limit (The limit is
defined in the beginning of the project in consultation with civil)
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Design and maximum operating conditions
Coordinate axis system considered for inputs
Dimensional details for piping designer to locate supports in piping model/layout.

3. Check list as per JE work instructions.

4. Following outputs
Load Cases
Restraint summary
Spring hanger report, if any


5. Stress critical line list extract for the lines analysed


6. Piping material specifications

7. Equipment drawings with allowable loads, if available

8. PID



































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ATTACHMENT 10.1
CRITERIA FOR IDENTIFING CRITICAL LINES.
Note :
1. Load sensitive equipment include fired heaters,boilers / steam generators, Reformers,lined
vessels with lining of brittle material,non-ferrous equipment,Graphite heat exchangers,plate &
frame heat exchanger,Spiral Heat Exchangers,Equipment on load Cells etc.
2. Also include lines connected to nozzles having differential settlement / Thermal displacement
more than 12 mm.
3. Delta T refers to the differential temperature between the process piping and jacket.
4. Very large diameter pipes (dia / thickness >100)and ducts need to be designed using finite
element analysis methods.
5. Category M Fluids involve toxic and harmful fluids which are identified by process.These
services are lethal and hence critical.They need mandatory flange leakage calculations. To get
the loads at flanges,a computerised stress analysis is required.
6. For critical lines in seismic prone, plants refer Attachment 10.2 for categorisation.

SR
NO
Temperature
T, Degree C

Pipe
Diameter
D,Inch
NB

Piping
Material
Service and Description
1 All D > 2 All Category M (Lethal) fluid service per ASME B31.3 (Ref. Note
4).
2 All D > 3 All Piping which is exposed to winds of speed > 75 mph.(Ref
Note 5)
3 T < (-) 45 D > 3 All All Services.
4 T > 200 D > 3 All All Services.
5 T > 100 D > 16
(see note
3)
All All Services.
6 T > 65 D > 3 Non-
Metallic
All Services.
7 T > 65 D > 2 All Lines with pressure > 900 psig.
8A T < (-) 29 D > 3 All Piping connected to nozzle load-sensitive equipment, (see
note 1)
8B T > 65 D > 3 All air-cooled exchangers and rotating equipment (see note 1).
9 DeltaT > 27
(Note 2)
D > 2 All Jacketed piping.(D=Inner Pipe NB)
10
A
T > 65 D > 4 All Internally lined pipe (except glass lined).
10
B
T < (-) 29 D > 4
11 All All All Glass lined piping.
12
A
T < (-) 40 D > 4 Metallic

Underground Piping/Cross Country Piping.
12
B
T > 80 D > 4 Metallic

Underground Piping/Cross Country Piping.
12
C
T < (-) 29 D > 8 Metallic

Underground Piping/Cross Country Piping.
12
D
T > 70 D > 8 Metallic

Underground Piping/Cross Country Piping.
13 All D > 2 All Safety Relief Valve Outlet Pipeline.
14 All D > 2 All Pipelines connected to expansion joints or bellows (except
rubber bellows used for alignment purpose).
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ATTACHMENT 10.2
Categorization for Seismic analysis
Definition: Plant Piping located in earthquake prone areas of the country will experience accelerations
imparted through foundations, structures and various equipment. Criticai piping {toxic, flammable, high
pressure, high temperature, emergency) which must remain leak;tight or operable (deliver, control or
shutoff flow) during or following the event, have nozzle loads within vendor's set limits, have minimum
sway to avoid impact or interference with adjacent equipment / pipes / structures need seismic analysis to
determine the effects.
Based on Indian code IS 1893-2002, areas falling under Zones IV and V are categorized as "Severe"
while Zones II and III are prone to earthquakes of "Moderate" or "Low" intensity. The IS 1893-2002
guidelines for BUILDINGS to be seismically designed are as beiow;
For regular buildings, if the building height is greater than 40 m in Zones IV and V or greater than
90 m in Zone II and III ;
For irregular buildings, if height is more than 12 m in Zones IV and V and more than 40 m in
Zones II and III,
Method: Process Plants normally fall within the irregular building category and hence the piping and
equipment are to be analysed accordingly. To get realistic results, it is essential that seismic analysis for
piping be carried out using the Dynamic analysis method viz. Time History method or Modal Response
Spectrum method. Piping connected to tail columns/vessels, chimneys and any slender structure should
preferably be analysed using dynamic analysis. Long-run piping on tall slender structures (such as flare
piping on trestles) should be analysed using composite analysis. For toxic/lethal piping systems, the
seismic anchor movements also need to be imposed during the dynamic analysis. However for
simplification's sake wherever dynamic analysis is not mandatory by the client or the response
spectra cannot be derived from data available, seismic design can be done using the Equivalent
Static (static coefficient) method.

The seismic accelerations, response spectra and anchor movement values are to be obtained from the
Civil Group.
For seismic analysis, earthquake loadings shall not be considered to act simultaneously with wind. Also it
is to be noted that cross-country pipelines, buried piping & piping for nuclear installations will need
rigorous analysis and the selection criteria below does not apply. Refer LWI 220 for explanatory
techniques for seismic design of piping systems (under development)
Selection: With due considerations to fluid criticality and intended operation, in order to assess maximum
impact it is recommended that only critical piping with higher sizes (i.e. higher mass and/or at higher
elevations which in turn reflects as higher force) be seismicaiiy computer analysed. Since not explicit in
Indian codes, following guidelines are a conservative selection.

All critical piping systems aboveground with a weight (self+fluid+insuiation) greater than 410
kg/m (corresponds to a 24" STD schedule water filled pipe).

All critical piping systems above ground with any portion routed at a height (height as per the
above IS 1893 building categorization) with a weight greater than 210 kg/m (corresponds to a 16"
STD schedule water filled pipe). Give due consideration to piping connected to tall equipment &
piping routed on tall slender structures.
All emergency service critical piping systems above ground with any portion routed at or
greater than 25m with a weight greater than 110 kg/m (corresponds to a 10" STD schedule
water filled pipe).
Smaller critical lines (3" to 10") routed above 10 m elevation need to be seismically analysed
provided the wind load does not govern.
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Piping < 410 kg/m and below 10m elevation and non-critical piping can be considered as non-
seismic critical. Such systems shall be made rigid overall preferably by having every 2
Fld
/ 3
rd
support (appx 12m) as a seismic lateral restraint (guide) and every straight run (> 3 times
standard supporting span) with a longitudinal (axial) restraint. Equivalent Static Analysis needs to
be done only if peak spectral acceleration / static seismic coefficient is > 0.3 g, max
component weight is > 200kg and pipe centerline is > 1m.
Branch lines can be decoupled from the run lines if I
run
> 25 leaned where I = moment of inertia.
These guidelines are indicated graphically on Sht 2 of 2 of this attachment.












































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ATTACHMENT 10.2







Notes :
1. For site specific Zoning as per IS 1893, refer Project Initiation Checklist in Project
Procedure
2. If Dynamic Analysis is not mandatory by the client or the response spectra cannot be
derived from data available, Equivalent Static Analysis can be done. However, if
Equivalent Static Analysis yields uneconomical results, Dynamic Analysis methods
may be adopted to achieve realistic results.
3. Piping in this category are non-seismic critical. Systems shall be made rigid overall
preferably by having every 2
nd
/ 3
rd
support (appx 12m) as a seismic lateral restraint
(guide) and every straight run {> 3 times standard supporting span) with a longitudinal
(axial) restraint. Equivalent Static Analysis needs to be done only if peak spectral
acceleration / static seismic coefficient is > 0.3 g, max component weight is > 200kg and
pipe centerline is > 1m.
4. A Tall equipment (tower.etc) located at grade is analogous to a Building (RCC or steel
frame structure). Piping connected to be categorized accordingly.
5. Piping on tall slender structures (such as flare piping on trestles) should undergo
composite analysis.
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6. Emergency services are isolation/relief systems which reduce the potential of a major
hazardous accident such as emergency process control, emergency pressure relief,
emergency venting / blowdown, emergency shutdown, emergency purging / cooling, etc
classified as safety critical by Process.