Ne te a aks 323 ine Level 2 oie PROCEDURE for FLEXIBILITY ANALYSIS, ching Bcthod of Flexibility Analysis. ‘Method of Flexibility Analysis. + Tine Level : 4 ‘¥ feats of Anais -Clelation Report 1s 2 aT TiS Aton Loa f 135 Checking Method for Lines Around Equipment ore. ins" Litce Around Clim and Vera Vato 9135.2 Lines Around Horizontal Vessel (Exchanger, Drum 1353 Lines Around Reactor. 13554 Lines Around Rotating Equipment (Pump, | Tubine, Compre 1355 Lines Around Fumace. 1356 Lines Around Storage Tank. 135.7 Lines Around Air Cooler. 136 137 38 Bg 4. Ma 142 M43 1s. 131 152 153 134 16. Support Attachment. 18 Spring Hangers... 1s Branch Connection. 18 Miscellaneous. CHECKING OF CALCULATION... Complete Check - Level 3 - Calculation report. Simplified Check - Level 2.. : Review - Level I (To be checked by support group). USING CAESAR TI, Identification of CAESAR Files. Document Numbering. Unit System (7273F-FL) sss Setup File ( CAESAR.CFG).. APPENDIXES.k 4 » score ‘The purpose of this document is to clarify the general requirements for piping flexibility analysis to be performed for piping design of the KHARG ETHYLENE PLANT ~ KHARG OLEFIN, COMPLEX PROJECT. DOCUMENTS CODES AND STANDARDS All piping systems shall be evaluated and analysed in accordance with : ‘This design instructions * Applicable codes and standards listed in JOB SPEC 7273F-000-JSD-1300- 08 “Job Specification for Piping Stress Analysis" JOB SPEC 7273F-000-ISD-1300-10 “Job Specification for Piping Supports” 7273F-000-STC-1390-00 “Standard Auxiliary Piping Supports Hot Collection” 72T3F -000-STC-1390-50 “Standard Auxiliary Piping Supports Cold Collection” COMPUTER SOFTWARE, “CAESAR II Ver 4.50” for piping stress analysis. The working directory for the Caesar II analysis, files should be : CARISF Caesar.cfg (configuration file) 7273F Lil (units file) both should be in the working directory. These files should not be modified for any reason without approval from the lead stress engineer to insure all analysis are consistent, See § 15.3 & 15.4 the configuration and units files using Caesar II program. “FEPIPE Ver 4.1 for FEM analysis. DEFINITION OF THE TEMPERATURE FOR THE ANALYSIS ‘Temperatures Reference Temperature for Hot Line 0c Reference Temperature for Cold Line 255°C Maximum wall temperature from solar radiation 285°C Steam-out Temperature £110°C (hold) Note: Steam-out temperature shall be considered only when the design temperature of the line is less than 110°C. Piping connected to rotating equipments (such as pumps etc ...), with design temperature less than 110°C shall be considered disconnected during steam-out operation for stress analysis purpose. bel42 43 44 ‘Temperature Ranges for Thermal Expansion Data Expansion/Contraction data shall be calculated using the highest differential temperature between reference temperature and load case design temperature. When the design temperature Te is higher than mean average high ambient temperature 55 the temperature range Tris —————__ tr oc 55°C Te When the design temperature Te is lower than mean average low ambient temperature 0°C, the temperature range Tris : Te orc 55°C For uninsulated off-site lines at ambient temperature, the maximum solar radiation temperature shall be taken as maximum temperature, so the temperature range Tris : — te orc Te 85°C Operating Temperature The operating temperature of the equipment shall be used to evaluate the movements of equipment nozzles except for columns and in cases of ines supported on equipment, Caution : When the design temperature is very higher than the operating, refer to process ‘specialist for clarification. Installation Temperature The installation temperature to be considered is 27°C (for forces and moments evaluation on rotating equipment only).agp nee 61 63 BATTERY LIMIT A directional pipe anchor shall be provided at battery these points. it points, No displacement shall appear at In case of impossibility, the analyst should contact the concemed Operating Centre in order to determinate the location of the fixed point. SLUG LOADING A list of two phases flow lines is issued by Process Department. This document gives forces (including DLF=2) to be taken into account for each line when the slug occurs. ‘The concerned lines shall be reviewed by stress and support groups to evaluate: * Loads and support configuration ‘++ Loads table for Civil Work department Restraint design + Alllchanges of pipe run direction will require a securely stop and hold down facilities. ‘+ Hold down supports shall be provided on vertical parts of pipe. ‘+ Restraints designed for slug flow will allow movements due to normal operation condition + Loads due to slug effect and their direction shall clearly appear on stress isometrics. For force values to apply on piping components, use the calculation sheet: ‘7273F_slug force calculation_V1.xls ‘+ Special attention shall be given to hand over total loads (Operating + slug load ) to Civil Work and Support Groups. ‘+ The required stiffness, if necessary, shall be transmitted to Civil Work to avoid horizontal ‘movements of structure. Analysis ‘+ Particular analysis shall be performed on equipments where it is apparent that slug effect will significantly increase the total loads acting on the nozzle. + The resultant combined calculated stresses shall not exceed the allowable values defined as occasional case for Deadweight + Pressure + Slug ForceWIND EFFECT vy, Wind loading shall be considered only for large lines in exposed condition (lines larger than 24"0D or OD 600mm included insulation THK, at elevation above,10 meters. The loading effect due to wind pressure shall be considered to calculate the stresses occurring in the piping system and the loads acting on the restraints. (Nozzles and supports). Wind pressure versus elevation are tabulated in table shown in Appendix IV.8. SNOWLOAD (Ws) ‘Snow loads shall be applied only for cold outside lines for which design T° is below O*C and which are not protected by floor, equipment or others. The hereafter calculated value (Ws) will be classed as uniform load following Y axis (Ul) in a separate Caesar input file. See 7273F_000_CN3_CN2_1370_SAMPLE_A. Design snow load : 25 kg/m? The distribution of snow remaining on the horizontal pipe will take the shape hereunder, a reduction factor of 0.72 may be applied. Ws =(1x 0.5D + 1/2 x2x0.22D ) 25 Ws =(1 x 0.72xD)25 Ws = 18 x D Kg/m® = 180 x D Nim? Where D = outside diameter of pipe or outside diameter of pipe + insulation if exist m )10. EARTHQUAKE EFFECT ‘An equivalent static seismic analysis is required forall calculated lines. See Appendix IV. FRICTION EFFECT The effect of friction shall not be used to reduce applied loads. The additional loads due to friction at supports, restraints and equipment nozzles shall be considered when in judgement of the Stress engineer friction will have a significant effect. No credit shall be taken for frictional loadings when they will result in reduced nozzle loads. ‘The following friction coefficient shall be used to determine loads = Surface Coeticiont + Steel to Steet 0.35 + Polished Stainless Steel to Teton oa1. FLANGE LEAKAGE ASSESSMENT 11.1 Generalities All flanges on high pressure networks or/and which carry dangerous fluid will have to be assessed for leakage as per the equivalent pressure method. These criteria will be estimate by piping stress ‘man according to safety department. 4Fe — 16.Me = Pmo + Pa —— +=— (N/mm? Peq jo + Pegl < Peqt Te te ( ) Peq=Pmo+Peqi W+P+T+/-D1+/-D2+H+UT beeA Occasional static and dynamic loads: ‘+ Us seismic accelerations (unsigned load) + Wind (unsigned load) * Pressure safety system reaction forces (signed load) "Surge loads (unsigned load) + Slug loads (signed load) Flange loads => Permanent load combination + foccasional signed loads] or +/-occasional unsigned load Be care to not combined two or several no concomitant occasional loads.2 a 114 12.1.2 LOW TEMPERATURE CARBON STEEL Generalities In accordance with the chapter III (Table 322.2.2(3)) of ASME B31.3 code, an impact testing is not Fequired for carbon steel materials if + The design temperature is below 29°C and at or above -104°C. * The stress ratio does not exceed 0.3°S¢ In this case, the different stresses are checked differently. Stress criteria The point (3) of the figure 323.2.2B imposes to take into account the following load cases: Permanent static loads: ‘+ W: Weight (signed toad) +P: Pressure (signed load) + T:low Temperature (signed load) + Fexteral loads (signed load) ‘+H: Spring Hanger (signed load) * Ut: uniform loads due to snow on cold network only. (signed load) Occasional static and dynamic loads: +. U: seismic accelerations. Corresponding to the SRSS combination of the U1 (X direction), U2 (¥ direction) and U3 (Z direction) components ‘+ WIN: Wind (unsigned load). WIN (X direction), WIN2 (Z direction), Allowable stress checking : Absolute Combination of longitudinal stress due to permanent static loads ( pressure, dead weight and displacement strains) + occasional loads shall be less than cold stress value multiplied by stress ratio (0:3) In calculating longitudinal stress, the forces and moments in the piping system shall be calculated using nominal dimensions and the stresses shall be calculated using section properties based on the nominal dimensions less corrosion, The criteria is: W+P4+T+F +H + U or WIN <0.3*Se = 41.3 Mpa combined in ABS Remarks 1) In Caesar load case it is necessary to have by load case line only one of load cases described Here above, 2) All sif. In Caesar input shall be equal to 1 3) For displacement strains, refer to § 319.2.1 of code B31.312.2 LOW TEMPERATURE CARBON STEEL (LTCS ) + CONCERNED PIPING CLASSES In accordance with Chapter Ill (§ 3233.2) of ASME B31.3 code, impact testing of each product form of material for the following specifications have been done. 12.24 Piping cee BOL DBO2 BOI EBU EB21 ASTM pipe | 4333-Gr6 | A333-G6 | A333-Gr6 | A333-Gr6 | 333-Gr6 materials A671-CC60_| A671-cc60_| A671-CC60_| A671-CC60_| A671-CC60 Stress criteria ~ Spec.material ASTM A333-Gr.6 and A671-Gr.CC60 In accordance with Table A-1 of ASME B31.3 code, the minimum design temperature of this materials is -45.5°C (-50°F). But the EEMUA publication N° 153 (supplement to ASME B31.3) permit to reduce this Temperature to-S4°C. In this case, no particular stress analysis is necessary. If the process design Temperature is less than ~S4°C, the piping stress analysis shall be similar to (Carbon steel material shown in § 12.1. So the cold allowable stress shall be multiplied by the stress ratio 0.313, GENERAL PROCEDURE FOR FLEXIBILITY ANALYSIS 13.1. Checking Method of Flexibility Analysis The type of flexibility analysis is determined according Table 1: Critical Line list Criteria shown in 7273F-000-JSD-1300-08 “Job Specification for Piping Stress Analysis" The type of flexibility analysis is coded as follows : + Line Level 3 - Comprehensive computer analysis, + Line Level 2 - Simplified analysis + Line Level 1 - Empirical judgement 13.2 Method of Fles lity Analysis. 13.2.1 Line Level 3 For Line Level 3, a comprehensive formal analysis using computerized systems shall be carried out. A Stress Analysis Calculation Report is issued on form 7273R_000_CN3_CN2_1370_SAMPLE_A.XLS ‘See APPENDIX V - sample calculation report. 13.2.2 Line Level 2 For Line Level 2, a simplified piping flexibility analysis with documentation shall be carried out based on shortcut calculation by CAESAR. A simplified Calculation Report is issued in form 7273F_000_CN3_CN2_1370_SAMPLE_A.XLS with a calculation number and kept in a file for reference. Nota: page 2 and 3 will be removed from this form 13.23 Line Level 1 For line Level 1, a visual inspection method may be used. Visual inspection method shall be restricted to lines that are similar to others already cleared by short calculation or comprehensive method, or lines clearly possessing adequate flexibility by Virtue of small size, moderate temperature, flexible configuration. The flexibility may be checked by the use of charts or tables (see 7273F 000 WI 1300 17) and a shortcut calculation by CAESAR, iffneeded, in such a case the line may be upgraded to Level 2.(For stress report form refer to Level133 13.4 BS 13.5.1 Results of Analysis - Calculation Report Preliminary Stress Analysis, Preliminary stress analysis shall be performed during the layout phase. A calculation report is issued as “Issued For Review Stress Check” (IFD1, IFD2, status) This document is issued to relay stress piping layout and support comments for the detailed engineering phase. During the detailed engineering phase, the calculation report shall be updated against all major comments from piping and support groups (eventually from equipment and Civil groups) and re- analyzed. Final Stress Analysis After review against piping/support detailed design, allowable loads to equipment nozzle, Civil requirements all calculation reports are reissued as “Final Stress Check" (IFC status) Allowable Loads The loads applied at equipment nozzle shall not exceed the allowable values specified by the equipment vendor. ‘All nozzles on pressuiééssels" shall.be verified with allowable loads according to tables in 7273F-000-JSD-0400-001-"General Design Rules for Pressure & Atmospheric Equipment* Ifthe pressure vessel nozzle cannot accommodate the loads using rigid nozzle, the piping shall be fe-analysed using nozzle flexibility derived from WRC 297 or FEM (Finite Element Method) Program analysis, and calculated loads submitted to vessel vendor approval. The loads applied to rotating equipment shall be submitted to vendor approval, in case the load teria could not be met. The equipment nazzle loads resulting from wind or earthquake, each considered separately, in combination with 1) thermal and, 2) thermal plus weight plus pressure shall not exceed 150% of the ‘API or vendor speciied nozzle load allowable or loads according to 7273F-000-JSD-0400-001 Checking Method for Lines Around Equipment The following conditions do not make an exhaustive study of each case. These conditions shall be considered as a guide of the minimum requirements for stress analysis of lines around equipment. Lines Around Column and Vertical Vessel * Design condition + Start-up condition + Steam-out condition (Vessel hot, Line cold) + Wind effect (If necessary) + Earthquake effect + Hydrostatic pressure test of insulated piping with blocked spring support (If required) Line supported and guided from long slender vessel shall include the horizontal movement due to wind or due to earthquake. Nozzle loads shall be as per § 13.4.13.52 13.53 13.54 Lines Around Horizontal Vessel (Exchanger, Drum ..) + Design condition + Design condition by-pass closed In such case itis necessary to consider the temperature decay inthe piping, + Earthquake effect ‘+ Hydrostatic pressure test (If required) Nozzle loads shall be as per § 13.4. Lines Around Reactor + Design condition + Start-up condition ‘+ Regeneration condition + Wind effect (necessary) + Earthquake effect ‘+ Hydrostatic pressure test of insulated piping with blocked spring suppor (If required) Line supported and guided from long slender vessel shall include the horizontal movement due to wind or due to earthquake. Nozzle loads shall be as per § 13.4. Lines Around Rotating Equipment (Pump, Turbine, Compressor) ‘Two pumps with one spare : + Design condition Pump A and B hot + Design condition Pump A operating, Pump B Stand-By ‘+ Design condition Pump & operating, Pump A Stand-By + Earthquake effect For piping system having a stagnant portion itis necessary to consider the temperature decay. For steam traced portion, the steam tracing temperature shall be considered for “dead legs” All nozzle loads on connected rotating equipment shall be calculated in operating conditions and all supports close to rotating equipment shall be adjustable. Caution : where the design temperature is very higher than the operating refer to Process specialist for clarification. Nozzle loads shall be according to vendor allowable or applicable codes. For piping with gas service (connected to turbines or compressors) besides the normal stress analysis calculations, the following verifications have to be performed. Extra calculation to check cold alianment. In a calculation with ambient temperature and imposed spring hangers free to move, the displacements of the disconnected flange shall be less than to 10 mm Extra calculation to check pre-start-up conditions, Weight of piping working on equipment nozzle shall be minimized and checked by means of calculation in ambient temperature with spring hangers imposed. Rage 121355 13.5.6 13.5.7 Lines Around Furnace + Design condition + Startup condition + Decoking condition + Wind effet (necessary) + Earthquake effect + Hydrostatic pressure test of insulated piping with blocked spring support If required) Nozzle loads shal be according to vendor allowable or applicable codes. Computer analysis of piping systems connected to floating heater coilS shail include the header coil or an approximate model ofthe coil 2s a part of the systems and the effects of intemal guides and restraints. Header coils and connected piping system shall be independently balanced so that no dead load is imposed on the coil. Lines Around Storage Tank * Design condition * Settlement (Residual after hydrostatic test ) + Bulging effect + Earthquake effect (i required ) *+ Hydrostatic pressure test of insuleted piping with blocked spring support (ifrequired) Lines shall be analised with the following boundary conditions at tank nozzles furnished by tank supplier : + Stiffness coefficients of nozzle for axial load, longitudinal moment and circumferential ‘moment. ‘+ Radial movement of nozzle due to maximum service temperature and full of product. + Rotation of nozzle due to maximum service temperature and full of product. Allowable loads shall be according to the vendor allowable or applicable code. Lines Around Air Cooler * Design condition + Start-up condition (ifrequired) + Shutdown (If required) + Steam-out condition (if required) + Earthquake effect (If required) + Slug effect (Ifnecessary) + Surge effect (ifnecessary) + Hydrostatic pressure test Computer analysis shall include headers taking into account friction effect and tube bundle resistance, (P.T.F-E sliding plates may be used to reduce friction effect). Clearance at header ends to accommodate thermal expansion shall be checked (Presetting of header shall be indicated on vendor drawing if required). age 13SaSESTSEE SEE TEEETSECESERSSESSTESLOSESESESSTES ESSE STSESESESSTSSCESESOSCSESESETSTISEOEISE — _— 2 7 The loads calculated shall be according to applicable code or transmitted to the air cooler supplior for approval. 13.6 Support Attachment Trunnions welded to pipe may be checked as tees or modeled as per APPENDIX Ill fo get the applied loads. 13.7 Spring Hangers Spring hangers displacements shall be calculated in operating conditions and the characteristic (loads, spring rates, etc..) imposed in final calculations. For a proper determination of spring hanger loads, all weights of piping components shall be accurate, Where spring supports or hangers have been used for liquid filed pipe lines, an investigative weight (no contents) analysis shall be done, to include the previously calculated installed load plus the spring-rate for the selected spring. This analysis is to ensure that the spring reaction force, active when the pre-set lock pin is removed and the system has yet to reach its final operating conditions, will not over stress the pipe nor impose an overioad on the nozzles of strain sensitive equipment. ‘The load variation percentage to be used for calculations is 25%. For piping connected to rotating equipment, the above mentioned value shall be 12% maximum. 13.8 Branch Connection ‘The in-plane stress intensification factor (SIF) for other than right angle branch connection shall be increased as follows B 45° 60° In-plane SIF SIF (90°) x 1.225 SIF (90)x 1.15 ; B= smatier angle between axes of branch and en CAUTION : SIF of all elements framing into intersection shall be modified accordingly, 13.9 Miscellaneous + Donot use *+¥* type restraints (ascending movement free) in Caesar file. Supports that lit should be removed and the analysis re-analyzed. Generally do not model “gaps” at restraints. The clearance of supports on account of fabrication tolerances as well as the flexbliy rate of piping supports will only be considered in justified exceptional cases. + All specific in-line component weight’s (e.g. valves, strainers, meters, etc..) not readily available from suppliers or vendors shall have their weights estimated and the calculations filed. These shall be reviewed when vendor data is avaiable. + Those pipe systems which are subjected to sustained high pressure's shall receive special Consideration with respect to Bourdon pressure loading effects; as these will alter the bend flexibitiy and stress intensification factors. + Temperature of dummy support shall be the same 2s the installation temperature. Page 1414, 14.1 142 = i hia alysis réasons the maximum thickness of reinforcing pad may be increased up to 1.5 times the header thickness as per available thickness in the piping class. Lines with safety relief valves are to be calculated using forces given by manufacturer with Dynamic Load Factor (OLF). This factor shall depend on shape, size and mass of the components and the design configuration of the piping. Transient forces shall only be considered when in the judgement ofthe Stress Engineer they wil have a significant effect. CHECKING OF CALCULATION ‘Complete Check - Level 3 - Calculation report Check of basic data Design temperature, design pressure, type of fluid and specific gravity, type of insulation and specific gravity, type of test pressure, against the latest line lis. Check of mechanical characteristics Pipe diameter, wall thickness, pipe material, against piping specification. ‘Check caloulation from input data. ‘Modulus of elasticity, allowable stress, expansion data, weights Check input geometry. Check toad cases Normal operation, steam out case, hat cold case for pumps, case by-pass cold, transient case, slug case, occasional case ..., to ensure that the worst case has been calculated. ‘Check input data Nozzlelrestraint movements, nozzle sifiness, settlement, imposed loads: weight of fittings, wind effect, earthquake effect. Expansion joint configuration and stifness Type of tee Impact load of relief valve Check that pipe is adequately supported and restrained to control movements. ‘Check output results Check calculated stress Check that loads on restraints are suitable for standard supports to be used. Check that loads have been transmitted to civil/structural ciscipline Simplified Check - Level 2 Check of basic data Design temperature, design pressure, type of fluid and specific gravity, type of insulation and specific gravity, type of test pressure, against the latest line list. Check of mechanical characteristics Pipe diameter, wall thickness, pipe material, against piping specication, Check calculation from input data Modulus of elasticity, allowable stress, expansion data, weights Age 15143 Pipe entering nozzle (In case of Rigid nozzle analysis) RESTRAINT (Y/N) "Y" NODE 50 CNODE 40 FROM 50 TYPE A [ANCHOR] To 60Dx =200 TEMP #1 250.0 + TEMP #2 150.0 TEMP #3 -20.0 DIAMETER 10 WIISCH 12.7 Pipe entering nozzle (In case of flexible nozzle analysis) IN CASE OF FLEXIBLE NOZZLE ANALYSIS USE SIX STIFFNESS COEFFICIENTS DERIVED FROM WRC 297 OR FEM ANALYSIS FROM 50 RESTRAINT (Y/N) "Y" TO 60 OX=200 TEMP #1 250.0 TEMP #2 150.0 TEMP #3 -20.0 FROM60 RESTRAINT (Y/N) TO 70 DX = 204.0 RIGID (YIN) "Y" WEIGHT 820.0 NODE 50 CNODE 40 TYPE X ‘STIF 35000 NODE 50 CNODE 40 TYPEY, STIF 525000 NODE 50 CNODE 40 TYPEZ STIF 432000 NODE 50 CNODE 40 TYPE RX STIF 1613 NODE 50 CNODE 40 TYPE RY STIF 125E09 NODE 50 CNODE 40 TYPE RZ STIF 115E09 Age 3¢CONCENTRIC ECCENTRIC ACTUAL AVERAGE () PROPERTIES Example 1: Concentric 14° x 10" reducer model shown below between nodes 80 and 85, the average diameter and wall thickness Aug. Dia. = (144+10.75)2 = 12.375" X avg. Thk. = (9.52 + 9.27)/2 = 9.4mm The partial input for this reducer, is shown hereafter : FROM 80 To 85 Dx 400 DIA 12.375 wr 94 Page 32Example 2: The partial input for this reducer, FROM To ox by DIA wr Eccentric 8" x 6" reducer model shown below between nodes 135 and 140, the average diameter and wall thickness is 135 140 182 25.4 7.625 7.65 ‘Avg. Dia. = ( 8.625 + 6.625 )/2 = 7.625" Avg. Thk. = (7.11 + 8.18 /2= 7.645 mm x is shown hereafter: foge 3%L STANCHION AND DUMMY LEG MODELLING DIA = 20" WT=9.52mm DIA = 12" WT = 8.38 mm For long Radius o A14 Deg For short Radius -AB.18 Deg faye 34MODELLING : Input a rigid element AB, from Node 99 to Node 1099 The trunnion starts at node 1099 SIF Ouplane is applied at 1099 for both Inplane and Outplane bending moment ‘The bend is not stifened , except where SIF are calculated from FE/PIPE for which the bend shall be inputed as Type 2 ( as double flanged bends) Define all dummy legs at the end of input. The element AB is considered as cold in offset modefing, so the following mode using rigid element. AB is better. The user should make sure that the input description of the model is accurate, {Input and output plots of dummy legs always show it going to the bend tangent intersection point (100 in the example here above ) lage 35-DUMMY LEG (Continuation) FROM NODE 90 TO NODE 100 by -1000 DIAMETER 20.00 wiscH 9.82 BEND "6 RADIUS 762.0 Angle#! 0. Node@1_ 98 Angle#2 48.60 Node@2 99 TEMP_1 250. PRESSURE_1 10. FROM NODE 100 TO NODE 110 Ox 1500 DIAMETER 20.00 wiscH 9.52 Elsewhere at the end of input data FROM NODE 99 TO NODE 1099 Ox 168.1 DY 4905 DIAVETER 20.00 wriscH 9.52 RIGID “y~ TEMP_1 250. PRESSURE_1 10. RIGID WEIGHT 0. TeEMP_1 250. PRESSURE_1 10,BO - DUMMY LEG (Continuation) FROMNODE — 1099 RESTRAINTS (YIN) "Y" NODE 1100 CNODE To NODE — 1100 TYPE Ox 550, DIAMETER 12.75 WiscH 8.382 TEMP’ 20. PRESSURE_1 0. FROMNODE — 1099 SIFS&TEES (YIN) ¥ NODE 1099 TO NODE — 1100 TYPE 1 SIFS() 45 SIFS(0) 45 Dx -850. DIAMETER 12.75 WTISCH 8.382 TEMP_1 20, lege 37TRUNNION MODELLING WITH CAESAR II asa FIG. 1.1: For small diameter trunnions are modelled in the CAESAR input data of the tee and the Code stress is calculated at the intersection Node 60 for header and trunnion using SIF. The length of the trunnion include the radial length of the header, this is more flexible and satisfactory for standard trunnion welded to pipe diameter up to 12 " inches. For trunnion diameter see § 16.4.1 DIA=8" WT = 8.18 mm 129¢ 393. 1.2! For large diameter pipe use the following more accurate modelling nnion Modelling Rigid element from Node 60 to Node 1059 * Flexible element from Node 1059 to Node 1060 ( Trunnion characteristics ) SIF Outplane is applied for both inplane and outplane bending moment at Node 1059 and at Node 60 FIG. 4.2 DIA = 12" WT = 8.38 mm DIA. = 20" WT=9.52 mm FROM NODE 50 SiFs & TEFs (YIN) YH Nowe 60 CNODE TO NODE 60 TYPE 1 SIF() 44 by — -1500 SIF(o) 4.4 DIAMETER 20.00 WTISCH 9.52, TEMP_1 250. PRESSURE_1 10. Pose 39= TRUNNION (Continuation) FROM NODE 60 SIFs& TEs (VIN) Y TO NODE 70 DX -2150 DIAMETER 20.00 WTISCH 9.62 TEMP_1 250. PRESSURE_1 10. Elsewhere at the end of input data FROMNODE 60 TO NODE 1059 DX 254 RIGIO WEIGHT 0. DIAMETER 12.00 WTISCH 8.38 TEMP_1 250, PRESSURE_1 10. RIGID™ NODE 60 CNODE TYPE 1 SIF@ 44 SIF(o) 4.1 Page 4o= TRUNNION (Continuation) FROMNODE 1059 RESTRAINTS (VIN) TO NODE 1060 ox 300 DIAMETER 12.75 NODE 1060 CNODE TYPE Y WTISCH 8.382 TEMP_1 20. PRESSURE_1 0. FROMNODE 1059 SIFs & TEEs (Y/N) Y TO NODE 1060 Dx 300 DIAMETER 12.75 WTISCH 8.382 TEMP’ 20. PRESSURE_1 0. NODE 1059 CNODE TYPE 1 SIF 4. SIF) 4.4 Fase 41324 32.2 TRUNNION CALCULATION General ‘The purpose of this document is to clarify the procedure for calculation of Trunnions, Stanchions and Dummy legs ditectly welded to pipe. Procedure for Line Calculated by CAESAR II Piping Stress Analysis Program Trunnion Modelling : ‘+ Trunnions are modelled in the CAESAR Il input data of the line as a Tee. + For trunnion diameter see § 3.4.2 ‘« Stresses are calculated in corroded condition only in the header pipe. + SIF ( Stress Intensification Factor) to be used: ‘Trunnions without reinforcing pad shall be input as reinforced fabricated tee, as no weakening hole has been cut through the header pipe wall. Consequently, trunnions with reinforcing pad shall bbe input as reinforced fabricated tee with 1.5 times the actual header pipe wall. This intersection model in the analysis induce a more flexible intersection but a higher bending moment and consequently a conservative stress calculation. This is a satisfactory intersection model for standard trunnions up to 12 inches pipe diameter. See § 2 - Fig. 1.1 TRUNNION MODELLING For large diameter or where more flexible intersection model carry less load, and thus lower sttesses, a more appropriate flexibility model is to be used as follows. ‘Input a rigid element from the centerline of the header pipe to its surface . The trunnion piping starts at the end of this rigid element. There is no local flexibility due to the header added, Stress computed for the branch, is for the point at its connection with the header. SIF Out- plane is to be used for both in-plane and out-plane bending moment. The same SIF is to be applied at the centerline of the header. See §2-Fig. 1.2 If the analysis shows that the pipe may be overstressed, a more rigorous analysis by FE/PIPE. program is performed. Stanchions and Dummy Legs in Bends Modelling + Input a rigid element from the centerline of the bend pipe to its surface . The trunnion piping starts at the end of this rigid element. There is no local flexibility due to the bend added, Stress computed for the branch, is for the point at its connection with the bend, * For teunnion diameter see § 3.4.2 + Stresses are calculated in corroded condition only in the header pipe. Page 4D33 34 3.4.1 = ass sevommenaea in CABSAR Il, Si Out-plane is to be applied for both in-plane and out- plane bending moment of trunnion at the bend connection . If the analysis shows that the pipe may be overstressed, a more rigorous analysis by FE/PIPE, program is performed. See § 1.as an Example. Remark : = The stress due to axial force in stanchion is not intensified in CAESAR calculation (as per B31.3 Code ). As calculated with Finite Element Analysis program the stresses induced by axial force are not important for standard stanchion . + The modelling indicated in § 1 induced a bending moment from axial force in the bend due to the offset introduced to modelled the trunnion and the pipe exactly along the same axis. This is ‘conservative and may be a reason to model the stanchion in other way as indicated in CAESAR USER’ S GUIDE. Design Method Using TABLE 1 (see § 4.4.1 ) for Line Not Calculated by CAESAR II Piping Stress Analysis Program. This procedure is to be applied for standard trunnions welded to pipe, stanchions and dummy leg supports welded to bend. This procedure is designed to check trunnion loads by comparison with the allowable values calculated for all standards trunnions. See page 17 as an example. ‘When Line Temperature exceeds 343°C (650°F) consult Stress Engineer. For special case or where a pad is required the detail procedure should be applied, Detailed Procedure to Check Local Stress in Pipe Wall for Non Standard Trunnions and or Combined Piping Reactions (KELLOGG’s Method) Size Trunnion In general material for trunnion should be of the same as the pipe. ‘The minimum nominal size is one half the nominal pipe size. The use of reinforcing pad should be avoided. Prefer the use of two trunnions or a larger one in diameter. Do not use thicker trunnion to reduce the stress, this may cause higher local stress in pipe stress analysis section to redesign the trunnion . Prefer to increase the trunnion diameter, ‘The method is derived from KELLOGG's Method "Design of Piping System™ ‘The maximum loads used in the checking are those producing the maximum stress as per the load combination table hereafter forthe following See Sustained loads, Normal operating Occasional sustained loads Combined loads, Normal operating Ge 43‘ucusutae Loaas and wand/seismrc loads shall 0¢ added to give maximum absolute value. Check the allowable stress using the relevant case in theTable of Load Combinations here after For checking method see form sheet as a guide for stress calculation. See Trunnion Loading Calculation pages 22 t0 27. If the piping reactions cause excessive stresses in detailed analysis, this calls etheir a more Figourous FE / PIPE, ora redesign of the trunnion, ) STANDARD TRUNNION DIAMETERS REFER TO STANDARDS ws 07 PIPE DIAMETER TRUNNION DIAMETER DN. Nes [_am DN _|_NPS mm 50 2 32 | 40 112 |_ 48,20 80 3 80,90 50 z 6032 | 100 4 11430 | 80 3 80,90 150 6 168,30 | 100 4 114,30 200 8 219,00 | 150 6 168,30 250 wo | 20s | 150 6 168,30 300 | 323,80 | 200 8 219,00 350 14 | 355,60 | 250 10 _|_273,05 400 16 | 40640 | 300 2 | 323,80 450 ws | 45720 | 350 4 355,6 500 20 | 50800 | 400 16 4064 600 24 6096 | 400 16 406.4 Page 443.4.2 Table of Load Combinations for Trunnions Calculation as See gecatlecmmetl | geen eee tase vonn ase | gue | promis | ron, | Sir | ures? [moran] manne ‘Thermal Expansion or x x ae Restraint Movement = x ‘Normal Design Pressure % x x ron res = ZTE IDET a : ‘Test Weight full of water x Wind or Seismic x ass apf cesceseng | tm | isos fog ge omer alpen Fag 4S3.4.3 Loads for Calculating Localised Bending Stresses Circumferential | st oece | LOAD DUE TO LOAD DUETO Bending Bending pe DISPLACEMENTS EFFECTS (ihermat expansion, | Notes Moment ba (weight, wind, movements, ete.) relief valves, ete.) ti te ta x heh heh () x x Aah t15hy AAS ASS, a x H=lSfy Kalss, a 7 f=15fe hate « x Let hi) [hater 5h, OF) x x x LU tLO [fra fet 5h, (1) (2) A Where: & R= Outside radius of pipe (mm)* T= Outside radius of trunnion (mm) Tyyy = Corroded under tolerance thickness of pipe or pipe plus reinforcing pad (mm) Internal pressure at condition under consideration (design, upset, occasionnel or test) (Mpa) Section Modulus of corroded, under tolerance trunnion (mm’) Fase 46‘Am length (mm) Longitudinal Force (N) Circumferential Force (N) F, = Axial Force (N) My = Torsional Moment, (N.m) = Longitudinal Bending Moment, (N.m) Mc = Circumferential Bending Moment, (N.m) FLXL {oad due to longitudinal bending moment, (N/mm) Load due to circumferential bending moment, (N/mm) ee Sande ar Load due to the resultant moments in the longitudinal and the circumferential direction, (N/mm) Load due to trunnion axial force, (N/mm) Sa= Se=Vhi + fe ii Load producing maximum stress in the shell inthe longitudinal direction 4, = Load producing maximum stress in the shell in the circumferential direction Notes: 1) Displacement loads may either plus or minus, but shall be added to other loads numerically, disregarding sign, to give maximum absolute value. equal to or 2) The resultant load shall not be used iff, is equal to or greater than 3fc"or fo is greater than 2; In this case, the stresses due to longitudinal bending and circumferential bending shall be considered separately, with the maximum value controlling, Cege Ge34.4 Header Stresses : 5, Condition 2 Circumferential Bendingf, (N/mm) | fy NIA Longitudinal Bending Stress NIK Sy(MPa) Longitudinal Pressure Stress PxR NA S, (MPa) |°" — 20xTs, Combined Longitudinal Stre aes (ee) | ge <5, = 1379 Circumforential Bendinaf, (N/mm) | fa =1Sfa + h5Sa Circumferential Bending Stress Leh xVR | 76.44 S.(MPay PS TL Circumferential Pressure Stress PxR_ 20.24 Spe(MPa) 10* Tin Combined Circumferential Stress | 5 = 5,45, 96.65 Condition 1 Longitudinal Bending J, (N/mm) | f, =15f, +h Circumferential Bendinaf, (N/mm) | fz =15f.+Se 86.31 Longitudinal Bending Stress lg, a IXA x VR | 7145 Sy(iaPa) [7 Longitudinal Pressure Stress 10.11 S,,(MPa) _| Combined Longitudinal Stre onatudinal <(idba) | 517 5w #5 81.56 <5, = 206.85 eos ee ese nee a Circumferential Bendingf, (N/mm) |S HIS fe th Sa NIA Circumferential Bending Stress Lx f, xVR | ia ‘S,.(MPa) -— ? Circumferential Pressure Stress PxR NA (MPa) |" ~10xTa, Combined Circumferential Stes | 5. = NA <5, = 206.85 SIPS) 5.25, # Sy oy 59APPENDIX IIT 3.6.5 TRUNNION STRESSES - Case 2: Weight + Design Pressure + Thermal — (Normal Operating) Bending Moment (N.mm) MyaLxfmbere | 1892x109 Section Modulus under tolerance | 7 _2*1 564008. Z(mm') d Section Sten?) [S=7%tye0 X(4= turn) | 1290. Bending Stress S,(mPa) | s, Me 27.16 nz Shear Stress S,(MPa) 7.00 Equivalent Stress $,(MPa) 30.55 <5, = 206.85 Re 60es a es RIF Ld APPENDIX IV ~ WIND PRESSURE / ELEVATION Wind Basic Data / Wind pressure calculation As per Project Basic Engineering : 7273F-30-PP-206 “Basic Design Data” Basic wind speed 160 km/h (44.5m/s) Exposure Category D According to UBC 97, the design wind loading shall be: P=CxC,xq,*1, where, P =Design wind pressure at evel 10m C.=1,56 at level 10 m (Exposure and gust factor-Table 16-G) =I for DN<= 50 mm =0.8 for DN> 50 mm (Exposure and gust factor-Table 16-H) qe 1.226 kN/m? ( Wind stagnation pressure at 10 m -Table 16-F) Iw = 1,15 (Importance factor ~Table 16-K) P=220xC, (kN/m) Height Above | Wind pressure Ground Level (m) PIC, (kNim?) Oto 10 22 10 to 20 2.47 20 to 30 2.64 30 to 40 2.16 40 t0 50 2.86 50 to 60 2.89 60 to 70 2.93 70 to 80 2.99 80 t0 90 3.127273 ‘ooo | wi | 1300 | 006 Jal ws | 12 ample APPENDIX IV According to CAESAR II Technical Reference Manual 5-19 the total wind force F (kN/m’) on the element is : F=P.S.A where + Pis the design wind pressure as calculated in the table above + isthe pipe element wind shape factor; S: ,=1 for DN<= 50 mm 8 for DN> 50 mm (Exposure and gust factor-Table 16-H) + A isthe pipe element exposed area CAUTION : wind load are a function of the piping system elevation. By default, the first node on the first element in the model is at an elevation of zero. If this default is not satisfactory then the user should enter the coordinates of this point by activating the branch error and coordinate prompts on the control parameter spreadsheet. CASE | WADI-TI4PI (OPE) Operating CASE 2 W+PI (SUS) Deadweight + Pressure CASE3 UI (OCC) Seismic Load X CASE 4 U2 (OCC) Seismic Load Y CASE 5 U3 (OCC) Seismic Load Z CASE 6 WINI (OCC) Wind following X axis CASE 7 WIN2 (OCC) Wind following Z axis CASE 8 L1-L2 (EXP) Expansion range {Code Case CASE 9 L3+L44L5 (OCC) Resultant seismic load, SRSS combination CASE 10 L2+L3 (OCC) Sustened plus Wind X Combined absolutely, Code Case CASE 10 L2+L4 (OCC) Sustained plus Wind Z Combined absolutely, Code Case CASE 10 L24L9 (OCC) Sustained plus Seismic Combined absolutely, Code Case CASE 11 LI+L7 (OCC) Operating plus Seismic combined absolutely, hot restraint Sage 6varaF [ooo] wi] 1300 | o06 | al ws | “Ws ‘APPENDIX IV ~ EARTHQUAKE ANALYSIS Method of Analysis Seismic analysis may be performed by static or dynamic methods. ic forces may be established in accordance with The static coefficient “G” used to calculate sei the provisions of UBC Code 1997 Section 1630. See hereafter ‘An carthquake is modeled as having a “G load in the X and Z, horizontal directions and 2/3 G load in ¥ vertical direction. According to CAESAR Il Technical Reference Manvel 5-22 the earthquake static load are given in terms of gravitational acceleration constant gs. The system weight is tumed into a uniform load and applied in the two horizontal directions. The gravitional load option is activated by setting the "Uniform Load Input in g's flag to 1 " in Auxiliary Data Input (K-AUX ) Option 6 - Special Execution Parameter See CAESAR I Technical Reference Manual 3-111 + Piping shall be provided with sufficient flexibility beetween two anchor points, taking into account that the two anchor might respond in different modes during an earthquake. * Piping offsets, expansion loops, etc., are normally only provided for absorbing thermal ‘movements. Suitable limit stops shall be provided to restrict this movement in case of a seismic shock + Piping going through bund walls, building walls and floors shall be provided with sleeves large enough to allow for the anticipated differential movements due to seismic loadings. + Where additional restraints are required to give protection from seismic loads, these shall be provided by the use of conventional supports : * Guides and anchors, + Hold down retraining the pipe against jumping in case of seismic shock + Shock arrestors shall be kept to @ minimum * Spring supports shall be kept to a minimum Limit of Calculated Stresses due to Earthquake (Occasional Load) See Section 302.3.6 of the ASME 31.3 Code “The sum of the longitudinal stresses due to pressure, weight, and other sustained loadings Sy, and of the stresses produced by occasional loads, such as wind or earthquake, may be as much as 1.33 times the basic allowable stress given in Appendix A ™....” Wind and earthquake forces need not be considered as acting concurrently” The stresses due to the effects of seismic inertia should be combined by SRSS with the stresses due to pressure , weight and other sustained loadings. ‘Anchor motions : Effects of anchor displacements due to earthquake (stress amplitudes iM/Z)) should be combined withthe effects of thermal expansion and limited to Sq,tae [eos Da PSE PET an ae APPENDIX IV 21.2 Earthquake Basie Data As per Project Basic Engineering : 7273F-000-PP-206 “Basic Design Data” UBC Code 1997: Selected Zone 3 Seismic Importance Factor : for water, vapour, Inst. Air, Nitrogen, ... 1.25 = for Hazardous fluid type. Soil profil * According to UBC-97 Section 1630.2 the Lateral Force Fp on piping system shall be determined with the following equation : type: Se V=2.5 Co LW/R (Eq30-5) where: Z seismic zone factor (Table 16-1) = 03 Seismic Source Type C (Table 16-U) IN, =near source factor= I (Table 16-8) Cy = seismic coefficient (Table 16-Q) = 0.30 I =importance factor (Table 16-K) =1 (for water, vapour, Inst. Air, Nitrogen, ...) 1.25 ( for Hazardeous fuid type.) R = coefficient (Table 16-N or 16-P) = 3 W = operating weight of the piping system V =the total lateral force The g's factor is determined by dividing Eq 30-5 by W VAW = 2.5x0.30x1.25/3 = 0,31 8 Maximum g's=0.30 ‘The vertical component is two-thirds the horizontal value = 0,20ot Juee. 1p] Mataat eae sera yee ooo | wi | 1300 | 06 [al ss APPENDIX IV 5 2.1.3 Load Cases to be calculated to comply with ASME B31.3 Code Cases: Example: CASE | WsDI+TI+PI(OPE) Operating CASE 2 W+PI(SUS) Deadweight + Pressure CASE 3 UI(OCC) Seismic Load X CASE 4 U2(OCC) Seismic Load ¥ CASE 5 U3(0CC) Seismic Load Z CASE 6 L1-L2(EXP) Expansion range Code Case CASE TL3+L44L5(OCC) Resultant seismic load, SRSS combination CASE 8 12+L7(0CC) Sustained plus Seismic Combined absoluely,Code Case ‘CASE 9 L1¥L7(0CC) Operating plus Seismic combined absolutely, hot restraint . hoe 65wi | 1300 | 00s [a 12 APPENDIX V ‘TYPICAL BLANK FORM FOR STRESS ANALYSIS REPORT + For Level 3 piping stress analyse reports. Excel file 7273F_000_1370_CN3_CN2_BLANK.XLS ¢ For Level 2 piping stress analyse reports, use only pages 1,9,10 and add loads on restraints issued from Caesar outputs. STRESS ANALYSIS REPORT - SAMPLE CALCULATION REPORT + For Level 3 piping stress analyse reports Excel file 7273F_000_1370_CN3_CN2_SAMPLE.XLS