Basis for deciding Stress critical lines:

Stress analysis is a complex task and in any process unit there are a huge numbe
r of lines exist which runs from one location to other. Analyzing all lines will
take a lot of time which in turn will increase the engineering time and corresp
onding cost. So every engineering organisation in this field has set up some gui
delines for deciding which lines are to be stress analysed using software (Caesa
r II, Autopipe, Caepipe or Rohr II).
The main factors which decide stress critical lines are as follows:
Line design/operating/upset temperature
Equipment connection
Pipe and Equipment material
Pipe condition
Pipe thickness
Design/Upset pressure
Every organisation has their own guidelines and the guidelines vary from project
to project. The following write up will provide few criteria for deciding stres
s critical lines. This is only a idea of how the differentiation occurs. User ar
e requested to check project specific documents for use in any project.
Mostly the critical lines for which stress analysis is to be performed by formal
computer analysis consists of the following lines:
All Pump (Centrifugal-API/ANSI, gear pump, Screw pump) suction and discharge pipi
ng (4 inch and larger).
Centrifugal Compressor inlet and outlet piping.
Lines to and from steam generators.
Reciprocating pump and compressor suction and discharge piping.
Piping requiring expansion joints or other proprietary expansion devices.
Steam and Gas Turbine inlet and outlet piping.
Air Cooler inlet and outlet piping (3 inch and larger).
Process Heater inlet and outlet piping
Lines classified as category M as per ASME B31.3.
Piping subjected to high cyclic temperature conditions.
All jacketed lines.
stress critical
Lines that require nozzle load compliance as stipulated per applicable codes or e
quipment Vendor allowable (Heat exchanger, Pressure Vessel Connected systems).
Lines subject to dynamic loading (relief lines, line with large pressure drop at
control valves, surge pressure, slug flow, churn, two phase flow, water hammer,
flashing, etc.)
All Fiberglass, aluminium alloy, refractory or elastomer lined piping.
All piping systems connected to FRP, plastic, glass lined steel or brittle equipm
ent
Lines subjected to non-thermal movements (Expected differential settlement betwee
n structures, structure-equipment, etc., process equipment growth, header growth
, tower growth or other significant displacements, etc.)
All lines 8 and larger operating above 150 deg. C (300 deg. F) and greater.
All lines 20 and larger operating above 80 deg. C (200 deg. F) and greater.
All lines 36 and larger.
All lines operating below -45 deg. C (-50 deg. F) which require special cold suppor
ts.
All plastic lined piping systems. Special attention shall be given to add enough
additional supports to limit the external forces and moments in the flange conne

ctions to avoid an extra risk of flange leaks

Lines with special design requirements
All Safety pressure relieving systems 4 inch and larger (not including thermal re
liefs)
Lines judged by the lead piping engineer/stress engineer as not having sufficient
inherent flexibility
In addition, the piping effects of other conditions such as temperature gradients
that could cause thermal bowing or where piping is connected to equipment with
significant thermal growth may warrant detailed computer analysis.
For thin wall piping, if the D/T ratio exceeds 100, following requirements are ap
plicable: Design and support of piping systems using this specification should be
reviewed by a stress engineer. Support and spans of thin wall piping systems ar
e not covered by current Project practices and therefore must be designed for ea
ch application.
Stub-in connections per 304.3.2 thru 304.3.4 of ASME B31.3, are not allowed for r
un pipe with D/T greater than or equal to 100 and the branch diameter is greater
than one half of the header diameter.
Lines connected to non-ferrous equipments.
Underground process lines with more than 30 degree difference in between design a
nd ambient temperature.
All vertical lines connected to vertical vessels that require pipe supports or gu
ides from that vessel.
All lines 4 inch and larger subject to external pressure or vacuum conditions.
All lines subject to vibration, as specified by Process, due to high velocity flo
w, high pressure drop, water hammer or mixed phase flow.
All lines that are connected to equipment constructed of thermoset or thermoplast
ic materials or that is glass, refractory, or elastomer lined.
All pressure containing non-metallic lines.
All flare line headers
Lines for which an Alternative Leak Test has been specified.
Many organisations have the practice of dividing these critical lines into three
groups based on their criticality:
Highly critical lines or group C1 lines: Must be reviewed thoroughly
Moderately Critical lines or group C2 lines and
Lower critical lines or group C3 lines