Trunnion Checking or Dummy Checking during stress

analysis of a piping system

Trunnion supports are one of the most frequently used pipe supports in process piping industry. This
support is widely used in piping industry due to its ease of construction and erection. The construction
and erection of a dummy supports is very easy because you have to simply weld a pipe (normally one or
more size less than the parent pipe to which it is to be welded) with the parent pipe. However the load
bearing capacity of this supports are not as comparable to civil supports. So every stress engineer must
check the weld point from failure viewpoint and investigate the ability to carry the piping load (mostly the
tangential and longitudinal load and corresponding moment). The chances of weld failure increases with
increase in trunnion length or trunnion height.

The load carrying capability of trunnion mainly depends on the following factors:

 Parent pipe and trunnion/dummy pipe diameter: With increase in pipe size the load carrying
capacity increases.
 Parent pipe thickness: With increase in pipe thickness the load carrying capability increases.
 Parent pipe material: With increase in parent pipe material allowable strength (Sh) the load
carrying capability increases.
 Design temperature: With decrease in design temperature the load carrying capability
increases.
 Parent pipe corrosion allowance: With decrease in corrosion allowance the load carrying
capability increases.
 Design pressure: With decrease in design pressure the load carrying capability increases.
 Trunnion/dummy pipe height: With decrease in trunnion height the load carrying capability
increases.

There are various ways in which trunnion checking can be done. However the Kellogg Method of trunnion
checking using excel spreadsheet is the most common among EPC organizations. In some organization
trunnion checking by WRC method is prevalent. In this article i will try to explain the steps and formulas
used while trunnion checking using Kellogg method.
Steps for Trunnion Checking:

 First of all run the static analysis in Caesar II to obtain the load values at trunnion nodes from
output processor. It is better practice to take the maximum value from all load cases (Sustained,
operating, design, upset, hydro etc)
 After that we need to calculate the bending stress generated on the pipe shell based on the
following Kellogg equation:

Sb=(1.17 * f * √R )/ (t^ ) ……(1)

1.5

Here,
Sb=bending stress in pipe shell
R=Outside radius of pipe shell
t=Corroded pipe thickness (actual pipe thickness-corrosion allowance) plus thickness of re-inforcement
pad
f=loading per unit length
Now from Caesar we will get three forces with respect to each trunnion; longitudinal forces,
circumferrential forces and axial forces. So accordingly we will have to calculate three f values as
mentioned below:
Loading due to longitudinal bending, f =M / (Π r^ ) ……(2)
L L
2

Loading due to circumferrential bending, f =M / (Π r^ ) ……..(3)

C C
2

and Loading due to axial force, f =P/ (2Π r)………..(4)

A

Where,
M =Longitudinal force obtained from Caesar * trunnion effective length
L

M =Circumferrential force obtained from Caesar output * trunnion effective length

C

P=direct axial force obtained from Caesar II output.

and r=outside radius of trunnion.

 Next step to to calculate all bending stresses using equation (1) for longitudinal (S ) , axial (S )
L A

and circumferential (S ) forces as calculated from equation (2), (3) and (4).
C

 Now Calculate longitudinal Pressure Stress (S =PD/4t) and Hoop Stress (S =PD/2t).
LP CP

 Now combine all these forces for proper load cases as shown below and compare the combined
value with allowable stress value (Normal industry practice is to take 1.5 times S value as the
h

allowable stress value where S is the basic allowable stress at design temperature from code
h

ASME B 31.3).

S + S + S <= 1.5 * S
L A LP h

S + S + S <= 1.5*S
C A CP h

And Trunnion Stress<=S h

Here trunnion stresses should be calculated as=[{32*Trunnion OD*√(M +M )} / {Π*(Trunnion OD^ -

L^
2
C^
2 4

Trunnion ID^ )}]

4

While checking trunnions or dummies you can find that major chunk of trunnions fails due to
circumferrential loads. So orient or place the trunnion is such a way that the circumferrential force on the
trunnion becomes very less to permit/allow greater trunnion heights. Otherwise try to reduce trunnion
height or increase trunnion size if possible. In my future post I will post one practical case study
explaining the trunnion calculation methods.
Hope you like this post, If you have any confusion/comment please inform in comments section.
A Brief Description of Sway Brace, Strut and Snubber
(Dynamic Restraints) for pipe supporting for process
industries

Whenever unplanned dynamic events occur, dynamic restraints carry the responsibility of protecting the piping and
other components from damage.

Undesirable abrupt movement of the components in the system can be caused by:

Pressure shocks from valve operation/ PSV

Water hammer

Boiler events

Pipe breakage

Wind load

Mechanical vibrations transmitted from pumps, compressors, turbines or other process equipments.

Seismic events

Fluid disturbances

Explosions etc.

Dynamic restraints are specially designed to absorb sudden increase in load from the pipe and transfer into the
structure and to dampen any opposing oscillation between the pipe and the structure. These restraints are not
intended to carry the weight of pipe work and should not impede the function of the supports. Dynamic restraints are
required to be very stiff, to have high load capacity and to minimize free movement between pipe and structure.

The main supports that make up the dynamic restraints for process piping are-

1. Sway Braces

2. Hydraulic and Mechanical Snubbers

3. Rigid Struts

4. Clamps

5. Welding Clevis etc.

In the following paragraphs we will discuss in brief about Sway Braces, Rigid Struts and Snubbers.

Sway Braces:

Sway braces can be defined as spring loaded units mounted on pipe work which are used to limit the swaying or
vibration induced by external forces (vibration force) by applying an opposing force on the pipe. They are double
acting variable spring units which can handle both tensile and compressive loads. It is commonly used to allow
unrestrained thermal movements while “tuning” the system dynamically to eliminate vibration. It could be pre-
loaded in the cold or installed position, so that after thermal pipe movement (growth) it reaches the neutral position
and the load on the system in the operating (OPE) condition is negligible (almost zero).

The construction is fairly simple, the unit has two piston plates: one on either side of the helical coil compression
spring connected by a single piston rod.

Fig. 1: Schematic Representation of Sway Brace construction.

If a tensile load is applied, the top piston plate is pulled down causing the spring to compress & if a compressive
load is applied the thrust nut/rod coupling pushes the bottom piston plate to push up which causes the spring to
compress. Therefore in both of the situation the spring gets compressed but due to design (see cut away section
above) the unit is capable of handling both compressive & tensile movements /forces.

The spring is pre-compressed (usually a full inch =25 mm) providing an initial force (preload) that instantaneously
opposes vibration. Whenever any movement from the sway brace neutral position occurs it is opposed by a load
equal to the pre-load plus travel from the neutral position times the sway brace spring constant. To explain it further,
if the piping load on the sway brace is less than pre load then there will not be any line movement. If the load is
equal to preload then the line will be on the verge of movement, but then also the line will not move. If the load is
more than the preload the line will deflect causing the spring to compress further. The deflection of the spring / pipe
in this case will be as given in equation 1.

Pipe deflection= (piping load – Pre load) / spring rate Eqn 1

So there is no pipe movement if the load is less than the preload and with load in excess of preload the deflection is
as given in Eqn 1.

When sway brace with a preload P is installed in a pipe there is no force exerted by the sway brace on the pipe. But
for the pipe to have any movement in either direction along the line of sway brace installation it will experience a
reactive force equal to P plus travel from neutral position times the sway brace spring constant. It is desired to have
no force on the pipe during normal operation of the pipe. So sway brace are normally attached during normal
operation or adjusted to the nutral positon during normal operating condition.

When maximum allowed travel (usually 3-in. / 75 mm in either direction) is reached the sway brace locks
preventing additional movement and act as a rigid restraint.
The preload for LISEGA sway braces can be adjusted as per requirement at site. But for C&P or others the unit is
shipped after adjusting required preload.

The effect of sway brace on the piping system is to increase the K value in the
equation Mx2(t) +Cx(t) +Kx(t)=F(t)

This in turn will raise the natural frequencies of the vibratory modes & thus normally reduce the response of the pipe
to dynamic loads & vibrations.

The force required to restrain the pipe work can be calculated as follows:

If the pipework is vibrating with frequency f Hz at a maximum displacement (half amplitude) of x mm then, in
simple harmonic motion, the restoring force exerted by the pipework at maximum displacement (kgf) = 4π 2 f2 m
x/1000 g. Where m is the equivalent mass of the pipework in kg.

It is likely that a Sway Brace having a preload greater than this value willfully restrain the pipe at the support
location, while a Sway Brace for which this value is greater than the preload, but less than the maximum load will
have a significant effect.

Manufacturers normally recommend a specific size of sway brace for a pipe nominal diameter. If the exact
restraining force required to control the piping vibration is known beforehand then a more specific sway brace
selection is possible. The energy necessary to control the piping system is proportional to the mass, amplitude of
movement and the external force which is causing the vibration. From this relation the exact restraining force
required to control the piping vibration can be calculated and an appropriate sway brace size can be selected.

Sway braces need to be installed in operating condition. However, it can be installed in cold condition. But for that
case when the plant starts operating, the pipe may have thermal movements. This may cause the spring in the sway
brace to compress by an amount equal to the thermal movement/displacement. At this point the sway brace will be
exerting a force equal to the pre-load + movement X spring constant. The load need to be released by doing “Neutral
adjustment”. This can be achieved by rotating the Rod coupling shown above in a direction such that the piston plate
gets released & rests against the end plate. In this situation the sway brace will not exert any force on the pipe.
During shut down, as the pipe cools & gets in to the cold position, the sway brace will exert a force on the pipe as
the spring will get compressed. To summarize,

Sustained loads on sway brace = Pre-Load + Hot Deflection * Spring Rate

In OPE case the displacement allows thermal expansion and the sway assumes neutral position exerting zero or
negligible load on the pipe. i. e, Operating case restraint loads on sway brace =~ 0.0 (does not restrain thermal
expansion)

Main Application:

Sway Braces are mainly used to reduce pipe vibration amplitude and at the same time does not increase the
expansion stress in operating case. It prevents the pipe from vibrating at its resonant frequency. Typical examples
of using the sway braces are in the pipe line feeding the flare stack in a refinery. When gases at very high pressures
are passed in the pipe line in the flare stack, it tends to vibrate & the sway brace will try & limit the
vibrations. Every time the vibrating force has to act as opposite to the sway brace preload+ the stiffness multiplied
by distance moved from neutral position. When the line movement exceeds the sway brace becomes rigid and act as
a rigid guide in that direction.

The spring stiffness and preload is fixed depending on pipe size. However for special applications manufacturer can
change those values as per requirement.

Click here to visit Caesar Modelling Procedure for Sway Brace

Struts:

When we need to limit the displacement which does not effect in increase of thermal stress in operating condition or
when the disturbed displacement is at an axis normal to the thermal displacement it is preferable and less expensive
to use a rigid strut or strut. Rigid struts are selected to suit the force that they will resist and the space available to fit
them. The anchor point to the structure is the most simple to select since it is only dependent on the size of the rigid
strut. The pipe attachment is dependant on both pipe size and strut size but it is also influenced by the orientation of
the strut relative to the pipe arrangement.
The strut is often more difficult to specify because it may be resisting forces in the three primary axes, x, y and z. It
is therefore necessary to use some simple trigonometry to resolve the given forces into axial force acting on the strut
and to calculate the actual length of the strut between the fixing point and the pipe attachment. Because the strut is
held between two pinned connections its ability to resist compressive force is greater the shorter the strut is. A long
strut will have a lower safe working load in compression than a short strut. However its length does not affect the
tensile load capacity of the strut.

The strut is therefore selected by considering the direction and magnitude of the axial force and if compressive
forces are acting, the length between the fixing pins of the connections. After the the strut size is selected, the
welding clevis will automatically specified to suit the strut size. The pipe attachment is selected now by considering
the pipe size, the strut size and the connection requirements between the strut and the clamp. It is essential that the
strut can attach to the clamp without obstruction and any thermal movements are able to occur without the strut
interfering on the clamp. Therefore it is very important to consider the transition of the assembly during all expected
displacements.

Main Application:

Rigid Struts are used in Turbine and Compressor connected lines near the nozzle connections to take the advantage
of very less friction. Otherwise struts can be used as a substitute for guide supports where structure is not available
for using standard guides.

Click here to check the modelling procedure of rigid Struts in Caesar II

Snubbers:
The use of snubbers (Also called shock absorber) is preferred in thermally operating piping systems. In a dynamic
event, snubbers instantaneously form a practically rigid restraint between the protected component and the structure.
Resulting dynamic energy can at once be absorbed and harmlessly transferred while the operational displacements
due to thermal expansion and contraction must not encounter any noticeable resistance. Through the special function
of the shock absorbers, thermal displacements during normal operation remain unhindered (offers very little
resistance to pipe movement). When however a sudden impact load acts upon snubber internal braking device
engage, thus controlling the movement of pipe. Snubber is said to be “lock up” and in this condition the snubber acts
as a rigid restraint. When the load has dissipated, the snubber unlocks and again allows gradual movement of the
pipe. Depending on internal mechanism of working snubbers are of two types:

1. Hydraulic Snubbers and

2. Mechanical Snubbers

1. Hydraulic Snubbers:

Similar to an automobile shock arrestor the hydraulic snubber is built around a cylinder containing hydraulic fluid
with a piston (See Fig. 2) that displaces the fluid from one end of the cylinder to the other.

Displacement of fluid results from the movement of the pipe causing the piston to displace within the cylinder
resulting in high pressure in one end of the cylinder and a relatively low pressure in the other.

The velocity of the piston will dictate the actual difference in pressure.

The fluid passes through a spring-loaded valve, the spring being used to hold the valve open. If the differential
pressure across the valve exceeds the effective pressure exerted by the spring, the valve will close. This causes the
snubber to become almost rigid and further movement or displacement is substantially prevented.

The hydraulic snubber is generally used when the axis of restraint is in the direction of expansion/ contraction of the
pipe. The snubber is therefore required to extend/ retract with the normal operation of the pipe work. The snubber
has low resistance to displacement/ movement at very low velocities. The resistance to normal thermal movements
(pipe velocity less than 1 mm/Sec and with amplitude of vibration less than 3 mm) is less than 2% of the rated load
of the snubber.

Fig. 2: Hydraulic Snubbers.

1. Mechanical Snubbers:

Whilst having the same application as the hydraulic snubber, retardation of the pipe is due to centrifugal braking
within the snubber. A split flywheel is rotated at high velocity which causes the steel balls to be forced radially
outwards. The flywheel is forced apart by the steel balls causing braking plates to come together thus retarding the
axial movement/displacement of the snubber. Rotation of the flywheel is generated by the linear displacement of the
main rod acting on a ball-screw or similar device.

Mechanical snubbers (See Fig. 3) are used in cases of applications where human access is restricted, for instance due
to high radiation atmosphere in the nuclear plant or due to high elevation point where no scaffold is available &
maintenance work is not easy to do. No maintenance service is required for mechanical snubbers & are designed to
generate the required resistance force instantly on reaching threshold acceleration, to restrain a displacement of
piping caused by an earthquake or other dynamic events & resume its free movement as soon as the dynamic
displacement is suppressed while developing very little (a negligible level of) frictional resistance force during the
slow thermal displacement mode of piping.

Selection of Snubbers:

The snubber is influenced by the same factors that the rigid strut is, the magnitude and direction of axial force, but it
is also necessary to consider the thermal displacement the snubber have to undergo.

Again it is necessary to use trigonometry for calculating the force and the length of the snubber alongwith the actual
displacement applied to the snubber. Displacements in the primary axes cannot be combined simply to determine the
snubber movement/displacement; it is necessary to calculate the overall length of the snubber in the various installed
and operating conditions in order to determine the needed stroke.

After calculating the actual stroke it is good engineering practice to take a margin of excess travel at each end of the
design travel. So, Always select a snubber that is capable of allowing greater displacement than is theoretically
required.

Orientation of the snubber is also important for both hydraulic and mechanical types. Access to either lubrication
points or inspection points is normally required and must be considered during the design and installation of the
restraint. It may also be required to allow in-situ testing of the snubber for validating its functionality and so access
may be a permanent requirement.
 Fig. 3: Mechanical Snubbers.

For selecting proper Snubber, determine the minimum required stroke by taking the anticipated design movement
and adding an allowance for excess travel. This allowance should normally be at least 20% of the anticipated design
movement. Then select a snubber where the cylinder stroke is greater than or equal to the minimum required stroke
and the applied loadings in tension and compression are less than the allowable maximum loadings in tension and
compression for the size and length of snubber as shown in the catalogue. For intermediate lengths, allowable
compressive loadings may be determined by interpolation. The length of the snubber must be such that the
maximum angulations are not exceeded.

To calculate the required closed centres for the snubber, use the following formulae:

Closed Centres = Installed Centres — X

Where X = (Stroke – Design Movement in Extension) / 2 or

X = (Stroke + Design Movement in Compression) / 2

This method will result in the spare travel being distributed evenly on either side of the design movement.

Main Application:

Snubbers are normally used for reducing the damaging effects of Earthquake events.

Click here to check the modelling of snubber in Caesar II

Modeling of Sway Braces in Caesar II for stress analysis
I have already published a post explaining the basics of Sway Braces in my earlier posts. Click here to visit it again.
In this article I will explain the procedure for modeling Sway Braces in Caesar II. As I have mentioned already
that Sway braces are spring (pre-loaded) loaded units to limit the swaying or vibration induced by external forces by
applying an opposing force on the pipe. The sway brace is simulated by use of bi-linear restraint available in
CAESAR II. It will be discussed in the following section.

Note: Refer this article along with the earlier article on Sway Brace for proper understanding.

Modeling in Caesar II:

The steps involved in modeling a sway brace in Caesar are as follows:

Select the sway brace from catalogue depending on given pipe nominal diameter or depending on the force
calculated to restrain the pipe work. (Fig. SB45 as per C&P catalogue, reproduced in Fig. 1)
 Fig.1: Sway Brace selection Table from C&P Catalogue.

Mark a node (Node 10-Fig.2) at the location in the piping system where sway brace will be installed. Run
Caesar analysis and note down the displacement of the point in specified direction from cold to operating condition.
For the sake of example, let’s assume that CAESAR II calculated displacement from cold to operating position is
0.5 inch in +X direction.

Now in CAESAR II input spread sheet (See Fig. 2) check the restraints box and define bi-linear restraint (X2
for the assumed case) at Node 10 with CNode at 101. Here, K1 is the initial stiffness of a bi-linear restraint. Do not
enter anything on this cell as the restraint is assumed to be rigid. The value of K2and Fy to be obtained from
catalogue. Where, K2= Post yield stiffness of a bilinear restraint. When the load on the support restraint exceeds Fy
then the stiffness on the support restraint changes from K1 to K2. Fy = Yield Load. If the load on the support
restraint is less than “Fy” then the initial stiffness K1 is used. If the load on the support restraint is greater than “Fy”
then the second stiffness ” K2″ is used.

Define restraint X at node 10 with CNode at 101. Provide a gap of 3 inch (=distance the sway brace is able to
move in both positive and negative direction before it gets locked/ become fully rigid depending on manufacturer= 3
inch as per C&P catalogue)
 Check the displacement box and define the displacement for Node 101. It is the displacement for node 10 as
noted earlier (0.5 inch in X direction, leave other cells i.e., DY, DZ, RX, RY, RZ blank.).

Add D2 in sustained and operating load cases. Now run the analysis to obtain results.
Modeling procedure of Rigid Strut in Caesar II
0

Refer my earlier post “A Brief Description of Sway Brace, Strut and Snubber ” for basics of working and the uses of
Rigid Struts. This article will explain the step by step methods for modeling the Rigid strut using software Caesar II.

The steps involved in Strut modeling are as follows:

 Find out the direction in which restriction of movement is required (Assume X direction) and location of
the strut installation. For reducing thermal loads to be carried by rigid struts it is preferable to choose
thermal null points if feasible.
 Double click on restraints check box in Caesar spreadsheet and model restraint X with 0 mm gap and with
no friction. Keep stiffness K1 box blank.
 Run Caesar Analysis and found out the force in that node.

 Enter into any catalogue (like C&P, Lisega etc) and select appropriate rigid strut depending on that force
(For your reference strut selection table has been reproduced in Fig. 1 from C&P Catalogue).
 Obtain the stiffness value for the strut from the catalogue and enter this value in restraint stiffness (K1)
which u left blank in initial stage.
 Run the analysis to obtain results.
 Fig. 1: Strut Selection Table from C&P Catalogue.

Rigid Struts are used in Turbine and Compressor connected lines near the nozzle connections to take the advantage
of very less friction. Otherwise struts can be used as a substitute for guide supports where structure is not available
for using standard guides.
Snubber modelling in Caesar II

I had already explained the basics of snubber in one of my earlier post. A short description regarding hydraulic and
mechanical snubbers used in process piping industry are also discussed. Click here to read it before checking the
modelling procedure . In this article I will explain the step by step procedure for modelling Snubber in Caesar II.

“Static” snubbers have a support restraint called SNB following a translational direction in the restraint type field.
When a snubber is entered, the restraint fields in Ceasar II change as follows: Gap and Mu are disabled.

Snubbers are the translational restraints which provide resistance to displacement in static analysis of occasional
loads only. It is assumed that occasional loading is dynamic in nature, similar to a static seismic or static wind
loading. THIS SNUBBERS ARE INACTIVE FOR ALL EXPANSION SUSTAINED, AND OPERATING
STATIC CASES, AND ARE ACTIVE FOR ALL TYPES OF TRUE DYNAMIC ANALYSES, i.e. HARMONIC,
MODAL, OR SPECTRAL. These restraints will be active in all static load cases defined as occasional in the load
case list.

Static snubbers may be directional, i.e. may be preceded by a minus or plus sign. The steps for modelling Snubber is
mentioned below:

 Create a node where snubber is required to add. (Node 10)

 Run the operating cases without defining a snubber at that node.
 Note the displacement in all six degrees of freedom at the location (Node 10) where to add the snubbers
(Assume D1 is the displacement at that node at T1 temp and D2 at T2 temp).
 From input piping spreadsheet click on restraint check box and define XSNB/ZSNB etc as per requirement
at node 10 with a distinct CNode 11. It will appear as a guide in Caesar Sketch.
 Place displacements on the CNode (CNode 11) by activating displacement checkbox.
 Modify the load cases by including D1 everywhere T1 displays and D2 where T2 appears for Operating
load cases.
 For defining occasional stresses create the following load cases as given in Fig. 1.
 Run the analysis to obtain results.
 Fig. 1: Load Cases for systems having a Snubber.

Application: Snubbers are normally used for reducing the damaging effects of Earthquake events.