D Introduction to Pipe Stress Analysis A) Before we start 1. Stiffness = itis the ability of a material to resist deformation under stress. % —_Blasticity :- It is the property of a material to regain its or inal shape after Deformation when the external forces are removed, 3. Castiron Remelting pig iron + coke + fimestone Cupola - cast iron ; i Fumace € Tensile strength = 1000 to 2000 kg / om2 Compressive strength = 4000 to 10,000 kalem2 Shear Strength = 1200 kgfem2 Steel (Carbon Steel) {tis an alloy of iron & carbon, with carbon content uy 15% *A carbon steel is defi ipto. a maximum of ined as a steel which has its properties mainly due to its carbon content & does not contain more than 0.5 % of silicon & 1.5% of manganese. Stress f=PIA Where f = Stress, Nimm2 Per Force or Load, N A. Resisting Area, mm2 f= st a ms Where e - Strain, no unit shoe Change in length or the body, mm A -- 5 Original length of body, mn Pipe Stress Analysis In order to properly design a piping system, the engineer must understand both a system's behavior under potential loading, as well as the regulatory requirements imposed upon it by the governing codes. The ASME * ANSI B 31" piping codes are the result of approximately 8 decades of work by the American Society of Mechanical Engineers and the American National standard institute aimed at the codification of design and engineering standards for piping systems. The 8 31 pressure Piping codes (and their successors, such as the ASME Boiler & Pressure Vessel Section Ill nuclear piping Codes) prescribe minimum design, materials, fabrication, Assembly, erection, test & inspection requirement for piping systems intended for use in power, petrochemical / refinery, fuel gas, gas transmission & nuclear applications Why Do we Perform Stress Analysis There are no. of reasons. Few of them are — 1) In order to keep stresses in the pipe end fitting within code allowable levels 2) In order to keep nozzles loadings on aitached equipment’ within allowable of manufacturers or recognized standards ( NEMA SM 23, APL610 etc )- 3) In order to keep Vessel stresses at piping connections within ASME section VIII ailowabie levels. t :ae 4) 5) 7) in order to calculate design loads for sizing supports and restraints, in order to determine piping disptacements for interference checks. In order to solve dynamic problems in piping, such as those due to mechanical vibration, acoustic vibration, fluid hammer etc. 1n order to optimize piping design . D) BASIC STRESS CONCEPTS NORMAL STRESS 1) Longitudinal or axial stress is the normal stress acting parallel to the Jongit Longitudinal stress tudinal axis of the pipe. A specific instance of longitudinal stress is that due to intemal pressure. SL Where AUS Am = Su = P*AI/ Am design pressure, psig internal area of pipe, in2 gm * meial cross section area of pipe I (do*_ di =Ses Od ye (4o* ei * Ssu- Ps Admit where dm = [seed] g be [eat] oe ee For convenience pA = 7 oT: Ore Sia Eee ae i tt Oe 2) Bending Stress ending moment acting on cross sect., in-tb ‘istance of point of interest from neutral axis of cross section, in '= moment of inertia of cross section, in* E = young’s modulus, psi R = Radius of curvatures of beam S = Bending Stress Sts Myo | IForcicle IL = a (do ai*X) Maximum bending stress will where C is greatest Smax = Mb-Ro cba eee f = My Z= section modulus - Summing all components of fongitudinal normal stresses. Su = Fax + Fado My Am At Zz 3) “Hoop Stress. ® Yensity of pressure iameter of cylinder ngth of cylinder hickness of cylinder Sy= hoop stress. Force acting on longitudinal section = P* d*1 (1)Resisting force = Sg2*t*l (2) Equating eqn. 1&2 Prdtt= se2rt 4) Radial Stress. tt acts in the third orthogonal direction parallel! to the pipe radius. Radial stress, which is caused by internal pressure varies between a Stress equal to the int. pressure at the pipe's inner surface & a stress equal to atmospheric press at pipe external surface. Assuming that there is no extemal pressure, calculated as Sp e-Pazm=O radial stress may be Spa-f Sea P C4 B72 f2*) Bee cere cee eee Meee (e* 25) Note that radi uter radius of the pipe, where the bending stresses are maximized, For this reason, this stress component has traditionally been ignored Curing the stress calculation { +5) Shear Stress Shear, distribution prefile fv Tm Tenax = WiQ Emin A m™ Where a “Cmax = max shear stress, psi € V_ = shear force, Ib Q = shear form factor (dimensionless) 1.333 For solid circular section a ‘At neutral axis shear stress is max. & since this is the opposite of the case with bending stress since these stresses are usually small; shear. stresses due to force are traditionally neglected during pipe stress analysis. Shear stresses may are caused by torsional loads” SS My Mae wR Conan = C Where Mr = internal torsional moment acting on cross sect in — Ib C =dist. of pt. of interest from tensional center R = torsional resistance. in* =a ar (do Fai YD Be alMaximum torsion stress occur When C= Rg, Ca Mr. Ro Sead ee = Mt Zz Summing the individual comp. of shear stress = YQ Pr ( Cmax. Arn co 3 —) Failure Theories 1) Octahedral shear or Von Misses Theory : - Failure occurs when the octahedral shear stress in a body is equal to the octahedral shear stress at yield in a uniaxial test. a ect = > 3 deformation occurs Syieid Plast a3- imensiogal ‘stress state whenever the octahedral shear exceeds ITE Syieid 3 2) Maximum Shear Stress- Tresca Theory. Failure occurs when the maximum shear stress in a body is equal to the maximum shear stress at yield in a uneasily tension test.Motecutar pattem Iounstressed grain <— Slipping of one melecttat surface aver another afte fret application of sess 2 6 ‘Sipping of a second ee ‘molacufar sudace after a arnt ‘Ste a ‘second application of Dislocations besinning Binecisandtange € Altar many repeated applications of ‘areas the cislocations are ‘completely angled and the gran is “locked ‘Wah anather application of the rate, the grin tears” anda ‘ta¥gue cracks iniiared.= | ceo Figure 1-16 ( | ; Te Dae Gale TEST LOADING CURVE UntariaT Tens te Tenatte Test Test naentae Spectaea Figure L-i7 : 123) F) Plastic deformed occurs in 3 dim states whenever maximum shear shield stress exceeds. Maximum stress — Rankine Theory. Failure occurs when the max. Tensile stress in a body equal to maximum tensile stress at yield in an uniaxial tension test, Si = Syietd where gic largest densile stress. Plastic deform at occurs in a 3 — dimensional stress state whenever the maximum principal stress exceeds sHigid.yi exd- Fatigue Failure Steps in fatigue failure 1) Grain boundaries are high energy boundaries. 2) When high stress is applied plastic deformation starts 3) Plastic deformation within a grain that is both subject to a high stress & oriented sucti that the stress cause slippage between advancement layer in same pattern. 4) On the first application of the stress dislocation will move through many of the grains. 5) As stress is repeated more dislocation will move through grains ‘These dislocations tend to accumulate at grain boundaries. 6) Alter multiple stress application, the dislocation tend to accumulate at grain boundaries and eventually becoming so dense that the grains lock up causing a loss of ductility & preventing father dislocation movement, 7) Subsequent application cause grain to tear & form a crack, 8) Repeatative stress application cause crack to grow. unless Abated, the crack propagate with additional stress apptication until sufficientcross sectional strength is fost to cause catastrophic failure of material, Features of Fatigue Failure s) 1) Crack usually initiate at free surface. 2) When corrosion & fatigue occur simultaneously, the chemical attack greatly accelerates the rate at which fatigue failure of the section as a whole Cyclic reduction Factor Expansion stress range Seca FC SyYC + Suh) Where Se = expansion stress range, psi F = factor of safety, dimensionless Syc = material yield stress at cold temp, psi Shy = material yield stréss at hot temp, Psi > At same point in vicinity of 7000 cycles the ( Syc + Syh ) limitation intersects the fatigue curve for carbon & -alloy steel. The Allowable Stress range therefore must be reduced to fit fatigue curve for cyclic application with 7000 cycles or more. cycle Tree Ep ! TO 7000 fo 7001 TA 14-000 o"> (400! TO 22000 os 45001 TO 100000 os [100001 1% 20000 os 20000 TO 700000 Oe L7aanal ta _2adnogo | o°3 | dt4) Stress intensification Factors. Markle, who generated fatigue endurance curve, found that the fatigue failures occurred not in the middle of the test spans, but primarily in the Vicinity of the fitings of in that case, they also occurred at lower stress cycle combinations than for straight pipe alone. What is in-plane & out —plane?, re my A Y Point & x Plane Y-2->{n-plane Mo Plane xa-> out-plane- co | Ponta i Plane Y-2 — tnzplane clang DEE Me plane BM APE XH > Out plane M5, -r ovt-plane 64 Plone, x-2 —» Torsional plane + My > tyrsiomal an. @ Py Acc. to Boney Forge Paper on subject of SIF states that highest SIF occur when the ratio of branch to header radii is about 0. 7 2-0 : 1 . 1 Som — 16 ae) OF 10 AleStress intensification factor ( SIF) is the ratio of maximum stress intensity to normal stress. tensity to normal Sess Why do we consider SIF 2-4. SIF at Bend OVALIZATION OF BEND ( & - 4) Elbow tend to ovalize during bending 2) Outer fibers come closer to N.A. thus ML. reduces & section modulus As Smax = ™y ; = > Been J = Hheng.. as 2 cteereases , Sroax Tm eveases . =U (4% 4 ! = Cag -4,*) " 4 Be" sch go T= 21% - Ps sbary wh Me ~€ § cal¥ <0 | i i +wm A) 8) c) Code Compliance Primary Load Characteristics: 1) Force driven (pressure, gravity, spring force etc.) 2) Not self limiting. 3) Non—cyclic 4) Excessive primary load causes gross plastic deformation & rupture, 5) Failure many occur with single application of load (However indication of impending failure exists.) : 6) Allowable limit for sustained stresses are related to the material yield stress, Secondary Load Characteristics. 1) usually displacement driven ( thermal expansion, vibration etc. ) 2) Self limiting. 3) Cyclic ( except settlement ) ; 4) Allowable limits are based upon cyclic & fatigue failure mode and therefore limited based upon requireinents for elastic cycling after shakedown & the thermal fatigue curve.: « @ 5) A single application of the toad never produces failure d Code Stress Allowables / Equations: B 31.3 1) Sustain allowable stress Sa < Sy I Where SI Sh= hot allowable stress. Sho Syiad or tress due to sustain loads AL Suttimate( & 2) B 313 does not provide an explicit equation for sustained stress ngineer compute the longitudinal Pressure & then ensure that these calculations, but only requires that the e Stresses in the pipe due to weight & do not exceed Sh. Where Fax Mi © axial force due to sustained loads, Ib 't*plane bending moment due to sustained, inb .Mo = out-piane bending moment = in-plane out-plane intensification factorappendix D of B 31.3 = basic allowable material stress at hot (operating) temp. as per Appendix A of B 31.3 Sh is.defined as the minimum of ') 48 Sultimate at operating temperature i) 488 Sultimate at room temperature ill) 2/3 Syield at operating temperature iv) 2/3 Sield at.coom temperature 100% of average stress for 0.01% creep rate per 1000 hrs. 67% of the average stress for rupture after 100, 000 hrs vil) 80% of the min. stress for rupture after 100, 000 hrs. Expansion Allowable stress Range k fWhere SA = Computed expansion stress range f = Cyclic reduction factor for fatigue. Se = Cold allowable stress Sh = Hot Allowable stress 1255, 25S AMlowable Equation Expansion, stvess vange, : Where Mi = range of in-plane bending moment due to expansion j loads, in — tb Mo = range of out plane bending moment due to expansion loads, in — Ib . ¢ MT = range of tensional moment due to expansion loads, in-tb | GE Sc = basic allowable material stress at the installation temperature, as per Appendix A of B 31.3 Codes 1) Occasional Stress B 31.3 states that the sum of the longitudinal stresses due-to sustained & occasional loads shall no Separately of than sum them up,Afv ww Set iseel ) Lee a DLrwol, 2) Whatis Liberat Allowable? ut 7 According +0 Code Sas VAS Sc +1-25 Sn) P25 Se + o1as Sn y FF CSH- =f lisse owreht erst) SaéSh The tast term is added only i.e. sustained allowable is satisfied. This increase in the allowable-expansion stress has been termed as ‘LIBERAL STRESS ALLOWABLE * a [rorser 9.25 sh+Sh -st.) cf (eaesbe tor)TD) Piping Design for loading Types a) Design for sustain loads 1) Pressure Minimum Wall thickness Shoop = 2 x S longitudinal Hence, pipe thickness is sized for hoop stress tm=tt+e = C Where f tm = minimum wall thickness, in t = min, wall thk. required for pressure, in © = sum of allowances for thread or groov depth, erosion & manufacturer's tolerance , in for thin wall t 0 Important Rule of design WA if supports are placed as near as possible to concentrated loads, the effect of these loads from stress pt. of view may be neglected. But must still be considered for the support loads. 2) support should be located as close as possible to concentrated weights - 3) if pipe changes direction in the Batientals direction, consider % th tocation is on an elbow Haver this is not Yecommertiide to the bend sHFeening ¢ increasect lost actresses + 4) To obtain a sufficient stiffness in pipe supports, the pipe should be routed as close to the structure as possible Design for Expansion Loads : 1) Magnitude of Thermal load 4 — ~— ee Cbd cad A ax. ery 7 a LPOMENYS: length of stevtayel span in order to minimize eccentric, Best | | i | +Where A. = thermal axial extension of unstrained pipe, in “ linear thernal expansion from amibient to operating temp, infin 4 =length of pipe, in The axial force required to compress that growth is tA ceeree| cece A = Pe AE ( Where A. =axial compression of pipe under leading jin P= compressive load A = cross — sectional area of pipe, in™ & = modulus of elasticity of pipe mat, psi Equating equation 1&2 ot = PE or Pa ARK Be e.g. for 12° pipe , A = 14.58 in2, E=29E6, psi eC = 1.88 e -3, in/ in T=350F @ P= 14,58*29E6* 1.88 ¢3 = BOO ,000 Pounds In fig (a), no stress developed an no movement in fig (b). no load as pipe is free to move both the designs are not good. if we allow 99.8 % of the pipe’s desired free movement, the developed force would be C= 6:998D K BOO ,O0O = 1600 Pounds i i :2) Guided Cantelever Method S Hot Se < ou 2 Se = 6etSe Sac eee tt ia 2 = ft Sur a= THe me 4 oe ut 2 = 42> substitute OD in (2) Se = Geee m= @er 4 fie yO GEL t Me os where | = moment of of inertia of pipe, in 4 = length of leg absorting thermal growth, in = section modulus, in® = outer radius of pipe, in Note that mal 1) SE is independant of wall thickness of pipe,irt 2) Se decreases with square of the length of absorbing length Sg. Paz", senesto , t= to! Az if i Bree 3 x Corian) =o 123" Ses CKIMEC KGB. 37° * Coxe | I +e) ? In above eqn, we did not take into account the SIF at elbow if we consider SIF for elbow = 2.8 thenSeE= 2-8 * 17700 = 49600 P51 We compare it against SA. saz §(Cr+2S5 CSc 43h) ~ St) Conservatively Spa fF Cl2s So to2zssud Say for A 106 B Se = Su = 20,000 es) Sa = 30,000 PS! +9600 DY BO-000 In this case Se exceeds SA Hanger Design Constant spring constant spring hangers are used to support pipes of equipment subjected to vertical movement due to thermal expanision at locations where transfer of stress to othér support or equipment can be critical if load_variation exceeds 25% then a constan support _hanger_is fecommended This support has an internal pivot arm attached to a spring, as the pipe moves up or down, the moment about the pivot arm attached to a spring, as the pipe moves up or down , the moment about the pivot and therefore a constant force acting against the pipe weight. The drawback of constant spring is that they are often too expensive for the application therefore they are usually used only, when pipe movement is very large.2) Variable Spring In variable spring hanger, spring load varies some what as the pipe moves. aa ‘These springs are pre-set to some loads, providers support through hoot the range of pipe movement. ‘As pipe moves up, spring decompresses, load put by spring decreases. As pipe moves dow, spring compresses load put by spring increases.3) Spring Calculations _- cL= HUD kaw were 4 cLtk Baw - pms wae Yel, CL= cold or installed load, ib HL = Hot or operating load i.e. desired targét load to support balanced wt. at spring location k = spring constant Asn = travel or thermal movement Pine at spring location upward direction +ve Load Variation= | HUL~ CLI K Am AL RL V The variability of an individual spring can be controlled only by varying the spring rate How to select spring from spring table 1) Calculate the maximum permissible spring rate as : IKenas, 2) Find out spring size by looking at load. range 3) for that size spring, selet the spring series with a spring rate less than or equal to calculate above 4) calculate HL from cL = HL TESS & verify that the cold load also falls within the working range 5) If this is not the case, then try again with a different spring series.Remember while doing stress analysis with spring remember for fluid — rE with specific gravity less than 1.0 1) E) While doing hydro test, remove spring support & provide rest support insted Horizontal movement at hanger must be considered when designing a support in order to assure that the pipe does not move so for that it falls off the support Excessive use of spring hangers may create a dynamically unstable system due to lack of restraint stiffness. Note that constant effort spring supports have no dynamic effect ona piping system . In a liquid filled tine, the springs may be installed when the system is empty. in this case it is necessary to ignore the * actual ‘ cold load, and in some cases it may be preferable to adjust the springs in the field to carry the cold load once the system has been filled. Design for occasional load There are additional requirments for the evaluation of occasional loads or primary loads which are present for short duration of time, typically 1 % to 10 % of total operating time, failure criteria are typically the some for occasional loads a for sustained loads, except that creep failure is not a concern for occasional toads. Because of this the allowable levels for the absolute sum of sustained & occasional stresses 1) are the same aas those for sustained loads, but increased by a factor ( typically 15% to 33 % ) Wind Loading f= Peg x Sx Dsin® Where f = * pseudo static “ wind per lengih of pipe .tbvit | +2) Peq = equivalent wind pressure , psi = V2q% density of air, Abe, | Fe =O'074B Ibm [Pee a 282 INA v = Design velocity of wind Q = qravitational constant,3.2 ft/sec™ Dd © = angel of orientation between pipe & wind, where 0 to pipe ipe diameter ft represents parailel axis. Earthquake loading Static earthquake loads are determined in a mender very similar to static wind loads the static loading magnitude is considered to be in direct proportion to the element's weight Earthquake load magnitude are given in terms at the’ gravitational acceleration constant ie. g's if earthquke is modeied as having 0.5 g load in the X ~dir, than as force equal to one-half of the system's weight is applied to pipe unifomly in the x — direction. @IV) __ Design Considerations 4) Vessel Try to give axial stop to pipe connected to nozzle near the line just above the fixed end of vessel as shown so that the expansion of the pipe will be in the same direction as that of nozzle & pipe will follow the movement of nozzle. { Divection oF Expansion Sue 2) Pumps « Vertical Pumps Horizontal pump IX Reducers in piping system connected to pump should be iocated as‘ far away from nozzle as possible, taking the process I : §requirements into account. A Small pipe is more flexible & will" transfer lower lozzis to pump nozzle . Suction & discharge valves should be supported at the same deck at the pump itself. Try to isolate the pumps from * external * piping loads by eg. guiding in — place with centerline of shaft,CAESAR Il - Techaical Reference Manual Cold Spring Cold spring isthe process of offseting (or pre-loading) the piping system with displace- ‘ment loads (usually accomplished by cutting short or long the pipe runs between tovo anchors) forthe purpose of reducing the absolute expansion load on the system, Cold spring is used to do the followi redice the magnitude of loads on equipmeat and restraint, since oftc, only a single application of a large load is sufficient to damage these clements hot - feaction hot ae reaction reaction’ Temperature cold, reaction ae ‘SYSTEM WITHOUT SYSTEMWITH COLD SPRING COLD SPRING ‘Several things should be considered ‘when using cold spring: * Cold reactions on equipment nozzles due to cold spring should not exceed nozzle allowable. ‘The expansion stress range should not include the effect of the cold spring. ‘The cold spring should be much greater than fabrication tolerances. Note No credit canbe taken for cold spring inthe stress calculations since the expan sion stress provisions of the piping codes require the evaluation ofthe stress range, which is unaffected by cold spring (except perhaps in the presence of non- linear boundary conditions, as diseussed below). The cold spring merely adjusts the stress mean, but not the range, Many engincers avoid cold spring du to the difficulty of maintaining accurate records {hroughout the operating life ofthe unit, Furure analysts attempting to make field repairs Gr modifications may not necessarily know about (and therefore include inthe analysis) the cold spring specification. Due to the difficulty of property installing a cold sprung system, most piping codes recome mend that only 2/3 of the specified cold spring be used for the equipment load caleula. tions. 4 ‘Technical Discussions Poe See | i | -Nee Rae be Jitlucmee fro |