Stress Analysis Work Procedure - draft

Contents

 Scope
 General Analysis Methodology
 Procedural guidelines
 SAQ – Stress Analysis Query
 SATS – Stress Analysis Tracking system
 Critical Line List
 Caesar Input File naming procedure
 Stress Isometric markup
 Caesar Title sheet
 Caesar Output Compilation Program
 CPS tracking system
 Vessel Cleat Load chart
 Stress Analysis Report
 Stress Analysis Checklist
 Spring Numbering system
 Spring/SPS/ Specials datasheets
 Procedure for Visual clearance
 Technical guidelines
 Modeling techniques
 Standard Modeling techniques and analysis features for column
 Standard Modeling techniques and analysis features for exchanger
 Standard Modeling techniques and analysis features for pump
 Standard Modeling techniques and analysis features for air cooler
 Standard Modeling techniques and analysis features for compressor
 Standard Modeling techniques and analysis features for turbine
 Standard Modeling techniques and analysis features for reactor
 Standard Modeling techniques and analysis features for heater
 Trunnion modeling technique
 Reducer modeling technique
 Expansion Bellow modeling technique
 Struts/ Snubber/ sway brace modeling
 Insulation/ refractory on vessel – modeling
 Clad vessel and pipe modeling
 Weight of control valves and spec. blinds – Database
 Equipment Skirt modeling
 Philosophies
 Seismic Criteria and load cases philosophy
 Wind Criteria and load cases philosophy
 Hydro test Criteria and load cases philosophy
 PSV load cases philosophy
 Hot sustained Stress load cases philosophy
 Sway Criteria and Load case philosophy
 Special type of analysis
 Trunnion Stress Check Criteria
 Requirement of Spring Bottom out/ Lift off check
 Flange leakage check criteria
 FRP modeling and analysis philosophy
 Buried Pipe Analysis Criteria and philosophy
 Criteria for Dynamic analysis
 Thermal bowing/Cold pull
 Fatigue analysis criteria

Page 1 of 4
 Stress Analysis Work Procedure - draft
Scope:
In view of standardising the Stress Analysis procedure, the following document has been prepared. The
fundamental aim of this document is to act as a supplement to the Stress Analysis Procedure, 3PS-PL008 and
provide additional “Stress Analysis specific” guidelines to the Stress Analyst (in particular a new team member)

General Stress Analysis:

For easy job distribution and job tracking and effective documentation, area wise Stress Engineers need to be
identified before the start of a project. This Area Stress Engineer will have the responsibility of generating and
maintaining a Critical line List, Storage of Final Stress Reports, Issue and storage of Spring, Special Pipe
Supports (SPS) and Specials (Snubbers, etc.) to Documentation Control Centre (DCC). All stress related
queries for a particular unit to be routed through the Area Stress Engineer for that unit.

Procedural Guidelines:-

Stress Analysis Query (SAQ):

For any analysis required by piping involving the use of Stress Analysis, Piping needs to raise Stress Analysis
Query – i.e. “SAQ”. The piping requirement may range from complete analysis, or visual check or for loads in
existing support members or any kind of site problem. For any of these, piping needs to raise a SAQ.
The SAQ has to be raised by Piping through the “SATS”. The SAQ can be tracked through the same.

Stress Analysis Tracking System (SATS):

The SATS is a package developed for automating the process of generating and recording the SAQ. It helps in
tracking any SAQ generated and for extracting overall status/ progress reports.

Critical Line List (CLL):

The CLL is the basic document for the Stress Analysis function. It is a classification of the process/ utility lines in
the units based on the criticality criterion as per 3PS-PL009. It also records all the SAQ’s raised by the Layout
Engineer and has the complete history data for the SAQ closed, once completed by the Stress Analyst.
The Piping Lead Engineer on receiving the latest P&ID and the LDT for the concerned project/FCO should hand
over a copy for updating the CLL, to the Area Stress Lead Engineer, identified. The Stress Engineer updates the
CLL, and then the Piping engineer can raise an SAQ.
Consequently this will be made into an automated form, with a link to the SATS.
On the basis of the CLL, the Piping engineer in consultation with the Stress Engineer identifies the probable
critical subsystems and then gives a Calculation No. for the sub system, on which the Piping Engineer can get
the package number from SATS.

Caesar input file-naming procedure:

The current procedure is listed below.
The Caesar file comprises of 8 characters. The first character is the character assigned to the Complex, the
second character to the unit in that particular complex. The next five characters are the number from any line
number from the SAQ package. The last character is for the revision of the package.
eg. Package number – Dapa104c, Character “D” stands for Crude Complex, character “a” stands for 311 unit.
Characters “pa104” are from the isometric 311-PA104-18”-EC32EA-HC-50. And the last character is the revision
– “c” represents the revision 2 (after 0 and 1)

There has been a proposal for changing the current procedure, which is pending for decision. – Task pending
with JK.

Stress Isometric mark up:

The restraint types are to be marked up as per the Legend on the top right hand corner of the Stress Isometric.
All the process parameter details are to be written on the left-hand side space for the basic data. This has to be
filled for each new isometric.
The Caesar file name has to appear on the Stress Isometric on each and every sheet.
Nozzle allowable loads to be written on the Stress Isometric on the sheet which show the equipment nozzle.
A simple sketch of the equipment, with correct orientation to be drawn on the same isometric.
Spring (with type) and SPS tag. no. to be mentioned at location where its is given in the layout. Spring axial and
transverse movement to be written on the stress isometric.

Page 2 of 4
 Stress Analysis Work Procedure - draft
The axial and lateral displacements as per the checklist to be mentioned on the stress isometric.
Vertical movement of pipe in column lines (difference between CNode and Node) to be mentioned.
Existing lines and new lines need to be highlighted clearly on the Stress Isometric.
Any weights of Blind Flanges/ Spectacle Blind/ Control Valves/ Inline filters/ PSV’s/ any weight not taken from
the Caesar Database to be mentioned on the isometric.
Any changes in the routing or support type in the given isometric to be highlighted on the isometric.

Caesar title sheet:

The Caesar input file title sheet should contain the following things:

Client: RELIANCE PETROLEUM LTD. - JAMNAGAR REFINERY PROJECT

Project: Project name or the FCO number.
Analyst: XYZ
Isometric nos.:
Notes: Analysed for change in nozzle size/ routing/ new line/ vibration problem/ etc.
Connected Equipment - Flash drum bottoms-ME-RD311-V04-nozzle KO to Pump-MP-RD311-P04A/ B/ C –
pump suction line.
Old revision details: If file is revised then the reason of revision to be written, with any other salient features of
the old file.

Analysis conditions: Design temp. : Design press. :

Operating temp. : Operating press. :
Mention Hydrotest pressure in Hydrotest case.
Mention weights of rigid elements not taken from the Caesar Database, eg. spec. blinds or control valves.

Load Cases:
Analysed for deign, operating, siesmic, or wind loads.
Hot cold cases criterion.
Mention if checked for Hot Sustained Stress and the nodes at which line is lifting.

Mention by which Nozzle allowable standards, the nozzle loads are checked. Mention whether OK.
Mention if springs provided and for what (reducing nozzle loads/ hot sustained stress failure)

Mention any changes in the Caesar Configuration file.

Any other assumptions taken for the analysis.

Caesar Output Compilation Package (COCP):

The loads calculated by the Caesar Stress Analysis package are to be tabulated to be passed on to the Piping
and Civil Groups for the downstream design processes.
The Stress User needs to save the various output files generated by Caesar with a specific nomenclature in a
specific location in the server. The Caesar Output Compilation Package compiles the various kinds of static and
occasional loads into a tabular form and presents the data in a predetermined format (developed after detailed
deliberation with Civil Dept.) for passing on as a consolidated Load chart.

CPS tracking system:

Previously the loads for the various support nodes were being manually input in the CPS tracking system.
Recently however this system has been linked to the Caesar Output Compilation Package for automatic transfer
of the loads to the package.

Vessel Cleat Load Chart:

For the vessel cleats supporting the piping supports in other than Global axis, the actual loads coming on the
supports are to be resolved in the vessel cleat axis direction. This is done by the Vessel Cleat Load Chart and
the same has to be enclosed in the SAR.

Stress Analysis Report:

Page 3 of 4
 Stress Analysis Work Procedure - draft
The Stress Engineer on completing the analysis has to issue the Stress Analysis Report – SAR. On updating the
relevant fields in SATS, the Stress Engineer generates the SAR front sheet and along with the enclosures
prepares the final SAR.
The enclosures should include:
# SAR front sheet, duly signed by Stress Engineer, Stress Lead Engineer and Dept. HOD.
# Stress Isometrics duly marked up.
# Load chart compiled by COCP.
# Vessel Cleat Load chart.
# Restraint Summary Report for all relevant load cases.
# Spring/ Specials datasheets or SPS sketches, where applicable.
# Equipment/ Pump GA.s, Nozzle Orientation drawings, Equipment datasheets, Pump nozzle Load diagrams
wherever applicable.
# Copy of LDT used for referring to the process parameters.
# Any reference copy of e-mail correspondence referring to the particular analysis.
Standard format generated by SATS is enclosed.

Stress Analysis Checklist:

The Stress Analysis Checklist has to be filled while issuing the SAR. This checklist is for reference of the Stress
Engineer only and not to be issued to Layout group.
Standard format is enclosed.

Spring Numbering system:

The Spring/ SPS/ Special tag naming procedure is as per guideline P-EP-PL-060-0A. The tags issued carry the
letter “Y” to differentiate the tags issued by Bechtel.

Spring/ Special Pipe Support/ Specials datasheets :

Any Spring designed by the Stress Analyst has to be checked for constructional suitability in consultation with
the Layout Engineer. Also the designed spring needs to be checked with Pipeworks group for actual availability
in the yard. If available the datasheet will carry the relevant stock code on the datasheet with a comment “Issued
for Construction” Also the stress analyst will have to check if any other spring is suggested by the Pipeworks
Engineer for substitution. If a new spring has to be procured then a new stock code will be given by Pipeworks
Engineer and the datasheet should carry the comment “Issued for Procurement”
The final datasheet after signing off from Stress Lead Engineer and Dept. HOD to be handed over to the Area
Stress Engineer for issue to DCC.
Any change in the spring design due to any reason would call for a revision of the datasheet. the same to be
revised and reissued to the DCC.
Standard format is enclosed.

Any SPS designed by the Stress Engineer has to be sketched with details and the MTO and the sketch to be
handed over to the Support Engineer for arranging for drafting. The final datasheet after signing off from Stress
Lead Engineer and Dept. HOD to be handed over to the Area Stress Engineer for issue to DCC.
Standard format is enclosed.

For any speciality support, such as snubbers (both hydraulic and mechanical) designed by the Stress Analyst a
datasheet has to be prepared. The final datasheet after signing off from Stress Lead Engineer and Dept. HOD to
be handed over to the Area Stress Engineer for issue to DCC.
Standard format is enclosed.

The Area Stress Engineer will issue the datasheets to DCC with a specific drawing number with reference to the
guideline P-EP-PL-060-0A.

Procedure for Visual Clearance:

Pending……………………

Page 4 of 4