Stress Basics PDF

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PROJECT TECHNICAL
NOTES 2730-8230-TN-0001
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TECHNICAL NOTES
Contract: 1-14-2730/69
Client’s Name: ENOC Processing Company L.L.C. (EPCL)
Project Title: NAPHTHA HYDROTREATER REFORMER

Client
EPCL / NI / 1695
Reference:
Project
JEBEL ALI FREE ZONE, DUBAI, UNITED ARAB EMIRATES
Location:
REVISION 02 F1 F2
Signature Signature Signature
DATE 08/02/06 14/03/06 19/04/06
ORIG. BY MED MED MED MED MED
APP. BY DH DH DH DH DH
CONTENTS
SECTION SUBJECT
1. INTRODUCTION
2. SCOPE
3. DESIGN BASIS
4. STEAM OUT CONDITION
5. SCHEDULE OF CRITICAL LINES
6. METHOD OF ANALYSIS
7. EXCEPTIONS
8. BASIC RESPONSIBILITIES
9. BELLOWS or EXPANSION JOINTS
10. SPRING SUPPORTS AND SLIDE PLATES
11. PIPE SUPPORTS
12. DRAWING DISTRIBUTION AND PROCEDURES
13. STRESS CLEARANCE AND APPROVAL
14. COMMENTS ON DRAWING
15. DIFFERENTIAL SETTLEMENTS
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CONTENTS (Cont'd)
SECTION SUBJECT
16. EARTHQUAKE LOADS

17. WIND LOADING
18. DOCUMENTATION
19. STRESS AND PIPE SUPPORT PROJECT FILING SCHEDULE
20. STRESS PROGRESS
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APPENDICES:
1. EXTENT OF STRESS ANALYSIS - PIPING CONNECTED TO EQUIPMENT OTHER THAN

ROTATION MACHINERY AND AIR FIN COOLERS
2. EXTENT OF STRESS ANALYSIS - PIPING CONNECTED TO ROTATING MACHINERY

AND AIR FIN COOLERS
3. EXTENT OF STRESS ANALYSIS - PIPING CONNECTED TO TANKS (NO FLEXIBLE

JOINT)
4. CALCULATION FRONT SHEET
5. FW ALLOWABLE LOADS EVALUATION TABLE FOR

EXCHANGERS/VESSELS/DRUMS/PUMPS AND COLUMNS.
6. STANDARD CALCULATION FRONT SHEET FOR DOCUMENTED HAND

CALCULATIONS
7. MINIMUM DESIGN LOADS FOR VESSELS
8. MAXIMUM RECOMMENDED SPANS - CARBON STEEL
9. MAXIMUM RECOMMENDED SPANS - STAINLESS STEEL
10. EXPANSION COEFFICIENTS FOR STAINLESS STEEL
11. EXPANSION COEFFICIENTS FOR CARBON STEEL
12. CAESAR II CALCULATION SET-UP
13. SITE DESIGN CONDITIONS AND GOVERNING CODES
14. SPECIAL DIFFERENTIAL SETTLEMENT CONSIDERATIONS
15. STRESS NOMOGRAPH AND GUIDELINES
16. STRESS ISOMETRIC FORMAT
17. NOZZLE LOAD EVALUATION AT STEAM TURBINES
18. NOZZLE LOAD EVALUATION AT CENTRIFUGAL COMPRESSORS
19. PIPE SUPPORT LOAD LIMITS FOR TRANSMITTAL TO CIVILS
20. TYPICAL SUPPORT MARK-UP FOR 1-4 SUPPORT POINTS.
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1 INTRODUCTION
These notes apply to Process Plant covered by the ENOC Naphtha Hydrotreater
Reformer Project. The aim of this document is to identify a set of guidelines for Pipe
Stress Analysis. Additionally it will indicate the Engineering and Designer
responsibilities including activities to be performed in order to satisfy the scope of
work for detail engineering of the project and hence ensure the structural and
functional integrity of the piping system in accordance with the relevant Codes and
Standards.
2 SCOPE
These notes establish the range of piping to be analysed, the piping wall thickness
calculations to be made and the equipment loadings required. It outlines the
responsibilities of Piping Engineering and lists the documentation to be prepared for
the project. Reference is also made to the use of Expansion Bellows and Spring
Supports with particular reference to the terminal connection at various pieces of
equipment. Special aspects of analysis will also be discussed.
3 DESIGN BASIS
It is the responsibility of the Stress Engineer to ensure that piping is routed and
supported correctly so that no damage occurs to pipe and associated equipment
due to the effects of thermal growth, weight, pressure, slug flow, wind, earthquake,
vibration, shock, foundation settlement or any detrimental external loads.
Every relevant mode of operation for stress critical piping systems shall be
examined and every displacement stress range difference shall be considered.
The Minimum criteria for defining the minimum acceptable flexibility are:
• The maximum allowable stress range of the piping material.

• The maximum allowable forces and moments on the equipment to which
the pipe is connected.
• The maximum displacements are acceptable.
• Other criteria will be considered if relevant
3.1 Codes and Standards
All the Codes and Standards referred to herein shall be as stated in ENOC document
01-A-10010 – BEDD Data Sheets. Where conflict exists between the various Codes
and Regulations the more stringent requirement shall prevail.
The following is a list of the relevant Regulations, codes and standards:

(Further codes may be applicable).
3.1.1 ASME B31.1 - Power Piping (Use where shown on flowsheet)
3.1.2 ASME B31.3-2002 - Chemical Plant and Petroleum Refinery Code
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3.1.3 ASME VIII - Rules for Pressure Vessels
3.1.4 ANSI / ASME B16.5 - Steel Pipe Flanges and Flanged Fittings.
3.1.5 API 610, 9th Edition - Centrifugal Pumps
3.1.6 NEMA SM-23, API 617 - Steam Turbines.
3.1.7 API 661 - Air Fin Coolers.
3.1.8 WRC 107 - Welding Research Council Bulletin.
3.1.9 API 620, API 650 - Storage Tanks.
3.1.10 ENOC EDS-L-1. - ENOC Refinery Piping Standard
3.1.11 2731-59B50 - Pipe Support Standard.
3.1.12 BS 6399 - Wind loading/data
3.1.13 UBC-1 (1997) - Earthquake data.
3.2 Thermal Expansion
Temperature differential for flexibility calculations shall be maximum temperature

minus the DMT (Design Minimum Temperature) as specified in the line list.
Maximum temperature shall be taken as the greater of:-
1) Design temperature.
2) Normal operating temperature
3) Start-up temperature
4) Shut down temperature
5) Transient temperature
6) Steam out temperature
The minimum temperature differential to be used in flexibility analysis will be 500 C

minus DMT, where lines are insulated or 80°C where solar gain is a consideration.
Where a specific DMT is not shown in the line list, the engineer is to use the
Project MDMT of 1°C, as quoted in BEDD document, 01-A-10010 Rev. 0, Feb 05.
3.3 Installed Temperatures
Temperature range for determining moments and forces on equipment nozzles

shall be:-
1) From the installation temperature to the maximum defined in 3.2

2) From the installation temperature to the DMT.
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Site installation temperature(s) is listed in appendix 13.
3.4 General
3.4.1 Piping systems may be subjected to many diverse loadings. Stresses caused by
pressure, weight of pipe, fittings and fluids, external loadings such as wind loads,
settlement and thermal expansion and contraction are significant in the stress
analysis of piping systems. Generally most piping movements are due to thermal
expansion but all the above shall be taken into consideration during stress
analysis. Criteria for differential settlement and earthquake loads are noted in
section 13 and 14 respectively.
3.4.2 All relevant process design data is included on the process line list including
design, operating and upset temperatures pressures and density. The Process
Group shall nominate which lines are subject to slug flow, acoustic induced
vibration and subject to more than 7000 cycles in the plant life on the process line
list.
3.4.3 Special consideration shall be given to differential settlement due to the nature of
substrate to which the plant is to be built on. The engineer should pay particular
attention when crossing between different foundations/bases in order to
accommodate differentials. Please refer to Appendix 11 for information on
differential settlement across the site.
3.4.4 Piping systems shall be adequately flexible and wherever possible it should be
achieved by the natural flexibility of the pipework. If necessary the route of the
piping should be modified or expansion loops incorporated to obtain sufficient
flexibility. Only in cases where it is impractical to increase the flexibility to reduce
the equipment nozzle loads to an acceptable level, should a bellows expansion
joint be considered as a design solution. Any use of bellows must be discussed
with the Lead Piping Engineer and approved by the client. Refer to section 9.
Expansion Bellows shall not be used in Hydrocarbon service
3.4.5 When carrying out flexibility analysis, the worst process conditions shall be
considered. Process conditions which give rise to impulse loading such as
pressure surge or two phase flow should also be taken into account. Criteria for
steam out conditions are noted in Section 4.
3.4.6 The Line List will indicate the maximum design temperature to be used in any
thermal flexibility calculations. If any other temperature is used in these
calculations both the Lead Stress Engineer and the Project Engineer responsible
for the Line List should be informed.
3.4.7 The Stress Engineer shall calculate nozzle loading based on the condition that
results from using the minimum or maximum operating temperature. Nozzle
loads on various items of equipment shall be compared with the allowable load
criteria for various pieces of equipment. In case of multiple items of equipment
connected to a common header all possible operating permutations shall be
considered. Where actual nozzle loads are in excess of allowable loads, the
relevant equipment group should normally be consulted before the loading is
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rejected. For FW allowable loads, see Appendix 5.
3.4.8 Strain sensitive equipment (vessels, heat exchangers, reactors, tanks) at which
pipe runs terminate shall normally be considered rigid for pipework analysis. The
loads shall be calculated at the vessel shell / nozzle intersection for all classes of
vessel or heat exchanger. Where a vessel or heat exchanger nozzle is modelled
within the pipework analysis, this shall be treated as rigid. If allowable loads can
not be met, nozzle stiffness should be modelled within the analysis following
discussion with the appropriate equipment discipline. For tanks, nozzle stiffness
to API 650 shall be used along with the allowable nozzle load approval method.
3.4.9 In the case of pressure vessels and heat exchangers where the supplier is
designing a "non standard" piece of equipment the allowable nozzle loads have
been determined for each nozzle and are given in appendix 7. These allowable
nozzle loads are issued as part of the equipment requisition or mechanical data
sheets.
3.4.10 In the case of tanks, the nozzle loads shall be referred to Vessels Group for
review. Design follows the requirements of API 650.
3.4.11 In all cases the Piping Stress Engineer shall be responsible for the structural
integrity of the piping flange. Calculations to demonstrate resistance to leakage
under bending loads shall be carried out for all lines 18”NB and greater over
4000C and all lines greater than 24”NB at any temperature
3.4.12 Piping connected to machinery shall be flexible to ensure that the piping loads
transmitted to the machine are acceptable under all design conditions.
3.4.13 Pipework connected to pumps shall be analysed with both pumps in operation
first. A further one-off case, one pump in operation/one pump on standby shall
be run after consideration has been given to which of the pumps operating will
produce the worst case. The temperature of the line to the standby pump shall
be considered as either: -
a) The average of the design temperature and the low ambient where a warm up
by-pass is installed.
b) Minimum maintained temperature where specified in line list.
c) Half of operating temperature through half of the line, or up to the first block
valve, whichever is less; and from then on, ambient temperature.
3.4.14 In reviewing piping isometrics, or arrangement drawings, the Stress Engineer

shall keep in mind that the aesthetic design of the piping system is the
responsibility of the Piping Designer and therefore should be reviewed from a
stress standpoint only. Due care must be taken with the design of pipe supports
to ensure uniformity, access, aesthetics and consistency in line with sound
engineering principles.
3.4.15 Any changes requested in the piping system shall only reflect the need to ensure
code compliance, to produce loads within allowables for a particular item of
equipment, or to ensure plant uniformity/consistency where possible.
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3.4.16 In the case of any confusion in the Design Basis, the relevant Stress Engineer
shall consult the Lead Piping Engineer for clarification.
4 STEAM OUT CONDITIONS
4.1 “All lines within process unit limits shall be suitable for steamout at shutdown
without overstressing the piping or connected equipment. Steamout conditions
shall be 150°C at 345kPa (g), regardless of the pressure/temperature rating of the
steam used.” Taken from ENOC EDS-L-1.
4.2 For lines which are subject to steam out and are connected to equipment, the
following shall apply:
4.2.1 Vessels
Connected piping may be steamed out with the vessel or independently. The
vessel may equally be steamed out whilst connected piping remains. Wherever
possible a one-off worst case of the following shall be run.
a) Line Hot, Equipment Cold, OR

b) Equipment Hot, Line Cold
4.2.2 Exchangers
Exchangers shall be considered to be steamed out with the connected pipe, thus
an "ALL HOT" case is to be considered. In the case of stacked exchanger, all the
exchangers shall be considered hot at the same time, for steam out design
purposes.
4.2.3 Pumps
All the pumps in a set including the standby pump will be simultaneously steamed
out up to the first block valve with the nozzles connected. The nozzle loads
generated should be below twice the allowables stated in API 610 9th edition,
Table 2-1 (the guidance in API 610 Appendix F must be followed).
5 SCHEDULE OF CRITICAL LINES
5.1 This is a list of all the lines that will be formally reviewed on the project. On this list
shall be recorded the status of lines analysed, the basis of their approval (ie visual
inspection, approximate calculation or computer analysis etc) and also the computer
run number where applicable.
5.2 On this project the line list is generated through a number of searches using an access
database. Line List data within the critical line list is to be updated by the lead stress
engineer in Reading upon receipt of a revised project line list. It is important that the
updating of the critical line list with respect to project line list revision is controlled by
the lead stress engineer such that he can maintain an overview of the project.
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5.3 The Stress Engineer will update the Excel version of the critical line index, by adding
engineer name, calculation numbers notes and progress status as the work
progresses. A hard copy will be readily available within the stress section for
reference, as well as the up to date electronic copy. The final copy will be produced
for permanent records at the conclusion of all engineering work on the project.
5.4 The Lead Stress Engineer in Reading will use the data from the excel spreadsheet to
populate and update the Master Access Database and report progress.
6 METHOD OF ANALYSIS
6.1 General
6.1.1 All systems not meeting the criteria in section 7 shall be analysed by visual
inspection, approximate calculations or a comprehensive method of analysis.
6.1.2 The Stress Engineer/Piping Engineer will review all lines and based on sound
engineering judgement, will determine the most economical method of analysis
required to ensure compliance with the Design Basis.
6.1.3 Approximate calculation methods may be applied in cases identified as category

2 on the stress critical line list. Approximate calculations may include the use of
charts, nomographs and simplified formulae etc. The objective of using these
methods is to demonstrate that recourse to accurate methods is not required.
See Appendix 15 for the FW approved stress nomograph and usage guidelines.
6.1.4 Acceptable comprehensive methods of analysis include computer and analytical

methods which include stress intensification and flexibility factors for all
components other than pipe and provide an evaluation of the forces, moments
and stresses caused by piping displacement.
6.1.5 The project approved program for the purpose of computer analysis is "CAESAR
II" version 4.50. This program computes complete stress analysis to the
requirements of the ASME B 31.1, ASME B 31.3 and CODETI codes and several
other relevant codes, and also provides a Code Compliance Report, when
requested.
6.1.6 All computer runs shall include temperature, pressure, weight and insulation if
any as a minimum. Guides/stops shall normally be modelled with no gaps and
friction in the horizontal and vertical planes shall be considered. Any specific
gaps must be noted on the stress sketches and the isometrics. Friction shall be
included in the analysis. Where friction causes problems with Caesar II analysis it
may be removed but should be noted on the calculation front sheet. The effects
of friction on supports and strain sensitive equipment shall be considered. See
friction table below.
Friction coefficients:-
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PTFE ON PTFE = 0.1

PTFE ON STAINLESS STEEL = 0.1
STEEL ON STEEL = 0.3
STEEL ON CONCRETE = 0.4
6.1.7 When commencing a new calculation please make a copy of 2730-CA-Template,

located in W:\Project\EPCL\2730\Gen\08Eng\054pipstress\02-Caesar II
Calculations. This enables consistent setup files and design basis. Any changes
to the setup file should be noted and justified in the calculation front sheet.
6.1.8 A summary of the template file configuration settings can be found in Appendix
12. Notably the ambient temperature is set according to the site conditions and
wind data is already stored.
6.1.9 Appendices '1', '2' and '3' show the method of examination required for all piping
systems covered by this specification and diagrammatically represent the
potential need for computer analysis. Lines that appear in the Category 3 region
are not included in the Critical line list; however visual analysis is required in
order to prove flexibility is adequate. This will take place during isometric sign off
for these lines.
6.1.10 For the calculation of stresses within the allowable stress range, the temperature
differential shall be taken as the difference between the maximum and minimum
cyclic temperatures of piping.
6.1.11 For the calculation of reactions, including connections to equipment, the

temperature differential shall be taken as the algebraic difference between the
maximum or minimum design temperature of piping for the thermal cycle under
analysis and the expected installation temperature.
6.1.12 Thermal movements between anchors shall be limited to 155mm. In exceptional

cases such as the high pressure steam system, where minimizing the number of
loops is of concern, 250mm of thermal movement is permitted. Thermal
movements at bends and branch connections should be limited to 75mm. Extra
long shoes shall be requested where movement will be excessive.
6.1.13 Considerable care should be taken when completing stress sketches, to inform
the piping designers of all large piping movements (>100mm), such that suitable
spacing can be provided. A stress sketch can take the form of a marked up
piping isometric as shown in Appendix 16. Significant Support loads and/or
Special Support requirements shall be added to a copy of the stress sketch and
transmitted to the civil/structural group.
6.1.14 At connection points between battery limits and Main service pipe racks care
should be taken to accommodate thermal expansion of both pipes. It is good
practise to provide at least a line stop at battery limits and the implications of this
must be design for.
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6.2 Piping at Pumps
Pipework at locations with multiple pumps shall be analysed for all possible
operating conditions, including operating and standby pairs of pumps.
The final mandatory check that the Stress Engineer must perform is a case with the
nozzles disconnected. Deflections at the free flanges must be less than 2mm in
any direction. This will ensure a relatively easy alignment of rotating equipment, as
very low loads will be imposed on the pump due to the weight case.
Refer WRC Bulletin 449, Guidelines for the Design and Installation of Pump Piping
Systems, for further information.
6.3 Piping at centrifugal compressors and steam turbines
6.3.1 General Design

The usage of the spreadsheets in attachments 19 and 20 is required for
centrifugal compressors and steam turbines.
6.3.2 Design Conditions
In order to develop the most severe loadings on the equipment, all possible
operating and upset scenarios shall be considered.
6.3.3 Temperature
Operating temperatures for each operating condition under consideration shall

be used in analyses. The support and anchor displacements resulting from the
expansion or contraction of the compressors and attached equipment due to
temperature changes shall be included in the analysis. Displacements of the
equipment nozzles shall be based on Vendor supplied data.
6.3.4 Pressure
Operating pressures for each operating condition under consideration shall be

used in analyses. For large diameter piping pressure effects (e.g. pressure
stiffening, Bourdon effects, etc.) can be considerable and shall be considered
in the analyses. Sustained stress shall be calculated using design pressure.
6.3.5 Allowable loads
Equipment nozzle loads shall be evaluated using the SM23 spreadsheets

shown in Attachments 19 and 20. These loads shall also be sent to the
equipment engineer for his records and approval. Initially the equipment
should be evaluated to 1 times SM23. Only after instruction from the
equipment engineer and/or equipment vendor shall other multiples of SM23 be
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used.
6.3.6 Friction Effect
A friction and non-friction analysis shall be considered for all large

compressors.
6.3.7 Stress Requirements
Stresses shall be calculated and evaluated according to the formulae and

procedures outlined in the ASME B31.3.
6.3.8 Piping Alignment
The final mandatory check that the Stress Engineer must perform is a case
with the nozzles disconnected. Deflections at the free flanges must be less
than 2mm in any direction. This will ensure a relatively easy alignment of
piping, as very low loads will be imposed on the equipment due to the weight
case.
6.3.9 Recommended Modelling
It is important when modelling these two types of equipment that the inlet,
extract and exhaust are modelled in three separate Caesar models. Care
must be taken to ensure that in all three models the global axis remain the
same to enable the transfer of loads from the Caesar model to the appropriate
spreadsheet is seamless.
In the case of the inlet and extract, (or inlet and other connection in the case of
the compressor), a connecting node must be placed followed by a rigid
element to the position of the exhaust. This means that loads at the exhaust
point can be read straight from the Caesar output and entered into the
turbine/compressor SM23 spreadsheet without the need for more complex
translation equation.
6.4 Piping at reciprocating compressors
The lead stress engineer shall be actively consulted in the review of reciprocating
compressor piping, due to the vibration issues associated with this equipment.
6.4.1 Layout
It is generally considered good practise to restrain piping after every change in

direction, to maximise the natural frequency of the piping system. Sufficient
spacing should be ensured to facilitate this.
6.4.2 Pipe Supports
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The use of pipe support PG-44 shall be compulsory on all piping 3” and above
within the scope of the vendor’s acoustic analysis. If an acoustic analysis is
not required PG-44 shall be used between the compressor and connections to
static equipment of significant volume. i.e. knockout drums etc.
Since the simplest way to dampen vibration in this piping is by adding

significant mass therefore larger beam sections and bigger foundations shall
be used.
Consultation with the civil and structural group shall be paramount during
support design.
6.4.3 Acoustic pulsation study
In most cases stress approved line routings complete with supports will need
to be sent away for an acoustic study at either the vendor or a specialist
company. It is desirable that minimum changes are required as a result of this
analysis and in order to ensure this, a natural frequency dynamic analysis
shall be performed in Caesar.
All natural frequencies of the piping should be above the frequency (f) below:
f=N x RPM
60
Where:
N = number of compressor stages
RPM = Motor RPM at operation.
It has been proven that use of the PG44 support and obtaining natural
frequencies above f, results in minimum design change after the acoustic
study.
6.4.4 Modelling Recip. Piping In Caesar II
Specific support stiffness have been developed in the past to model the pg44
type of support located in various positions. I.e. on solid concrete foundation
or mid span on a steel beam. These help to overcome differences in vibration
associated forces and the larger thermal expansion forces:
Support on grade level up to 1000mm elevation, on concrete plinth

Vertical stiffness and line stop value =109N/cm
Support on concrete beam Vertical stiffness and line stop value =108N/cm.
Support on steel beam Vertical stiffness and line stop value= 106N/cm.
Normal clamp tightening Horizontal and axial stiffness value = 104N/cm.
Guide (Hard Clamp tightening) Horizontal and axial stiffness value = 105N/cm.
Guide (PG-44+PG-1) Axial Stiffness value = 104N/cm.
Guide Stiffness value = 106N/cm.
6.5 Boiler and Power Piping
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Due care shall be taken to ensure that all P&ID’s are checked for ASME piping
code splits around steam generation systems and other power related piping. The
Process Engineering Department will mark up P&ID’s to show where the B31.1
transition occurs. The applicable code should be selected as appropriate within the
Caesar II model. B31.1 has significantly higher levels of conservatism and stress
allowables are dramatically reduced as well as other factors.
6.6 CCR Loop Piping
6.6.1 Creep
Equipment associated with the CCR loop is subject to creep design and stress
engineers shall be mindful of this. Every effort shall be made to ensure that
the attached piping is adequately supported such that the nozzle loads are
minimised in the sustained case.
Since the piping attached to this equipment is within the temperature allowable
of the code, there are no specific requirements to do anything special or
different in terms of piping flexibility analysis. However it is prudent to be
aware of these issues.
Specific Nozzle allowables shall be discussed with equipment group during

design to ensure acceptable pipe routings.
6.7 Other Considerations
6.7.1 Extent of computer analysis
Lines connected to strain sensitive equipment must be analysed by computer

to give accurate loadings for final review by the Specialist Engineers.
Engineering judgement shall be used to decide as to which equipment should
be treated as strain sensitive. In general, they shall include:-
6.7.1.1 Rotating equipment with nozzles ≥ 3"NB.
6.7.1.2 Thin walled vessels (e.g. corroded thickness < 5mm) with design temp 80°C &
above.
6.7.1.3 Heat exchangers with design temp 80°C & above.
6.7.1.4 Fired heater ≥ 3"NB.
All piping with wall thicknesses greater than standard weight shall be considered
on individual merits whether to be analysed by computer.
Computer analysis may be necessary where movements are large due to
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extraneous cause’s e.g. differential settlement of foundation etc.
Lines subject to large displacement imposed on them by the movements of other

lines or equipment to which they are connected may be assessed
comprehensively even though they may be below the limits shown in Appendices
1, 2 and 3.
Lines 1.1/2" NB and below shall be considered on their merits but in general a
visual inspection only will be sufficient. Lines 1.1/2 “and less, below 80°C will not
be considered for analysis.
6.7.2 Firewater piping
Firewater systems, whilst not subject to significant thermal loads, are subject to
high surge loads. The pipework must, therefore, be restrained frequently.
6.7.3 Relief Valves
Impulse loading to relief valve discharge is to be considered and suitable

restraints called for. Relief Valve forces are supplied by Instrument Department
after valve throat sizing. Constant RV loads associated with discharging to
atmosphere shall also be considered.
6.7.4 Thin walled piping
Thin walled piping is to be considered for shortened support spans and wear
plates. Reference should also be made to the Pipe Support Standard (2730-
8230-0003 (59B50)).
6.7.5 Complex piping items
If there is an apparent need to use complex piping items such as bellows,

expansion joints or snubbers the Stress Engineer shall investigate all possible
means of eliminating these devices. Equipment Engineers shall be requested to
supply strengthened nozzles, Process requested to minimize exessively
conservative design temperatures and pressures and Projects should be made
aware of such devices and the circumstances which result in these items being
specified.
6.7.6 Surge
Check the possibility of surge occurring in off-site lines as a result of valve

closure. Detailed information of surge forces to be supplied by process. Install
line stops at changes of direction to withstand surge forces and consequent
movement of the pipe.
The following are conditions that should be considered for slug flow:
1. Slug development due to start-up/shutdown.
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2. Slug build-up in condensate lines.
3. Slug development in relief flare systems (liquid relief).
6.7.7 Slug loading
A slug of liquid, with a mass (kg) and velocity (m/s), being driven along a piping
system has a momentum, and if it travels around a sharp bend or elbow, there is
a change in momentum.
The following formula may be applied to calculate the force acting on elbows:
Fr=√ρ a v2 (1)
where: Fr = Resultant force as slug strikes elbow

ρ = density of fluid
a = internal cross sectional area
v = velocity of which slug is travelling
Fr
It should be remembered that this force generated is an impact force and it is

suggested that formula (1) should be factored by a dynamic load factor ie
Fr=2 x √ρ a v
A full dynamic analysis should not be attempted if a system is acting close to slug
flow condition due to the complexity of predicting the ‘time period’ of slug
generation. However, as a minimum the first mode of vibration (natural
frequency) shall be above 5Hz. The routing shall then be presented to the Lead
Stress Engineer for further consideration of slug loading and additional
modelling/analysis
6.7.8 Flare systems
Flare systems must be reviewed with consideration given to the full temperature
range, and the possibility of slugging and shock loading criteria. ENOC
Requirements dictate that all flare branches shall be at 45°.
As a consequence of this and inline with FW standard practise Branches at 45°

shall have SIF’s evaluated and multiplied by a standard figure of 2.25.
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6.7.9 Hydrostatic testing
Hydrostatic testing of large bore lines, especially lines in vapour service, should
be given consideration with regard to additional loads imposed on equipment and
support structures. In some cases temporary supports may be required or in
extreme circumstances a pneumatic test may be an alternative (discuss with
projects, who will advise)
7 EXCEPTIONS
7.1 No formal analysis of adequate flexibility is required for systems described in the
following:
• Systems where the maximum temperature change will not exceed 30°C from
ambient or installed temperature.
• As otherwise accepted by applicable codes.
i.e 1) Duplicates that replace a system with a successful service record.
2) Can be judged adequate by comparison with a previously

analysed system.
8 BASIC RESPONSIBILITIES
8.1 Piping Engineering are responsible for the mechanical integrity of all FWEL Piping
Group designed pipe systems. A more comprehensive list of the steps in ensuring
mechanical integrity is as follows:
8.1.1 Produce schedule of critical lines as defined in Section 5.
8.1.2 Perform a minimum of visual inspection and check on all lines to ensure that
sufficient piping flexibility exists in accordance with the applicable design code.
8.1.3 Prepare the vessel clip schedule for all vessels where clips are needed and issue
to Pressure Vessels Group.
8.1.4 Perform a formal computational flexibility analysis on lines identified in the stress
critical line index as category 1, see Appendices 1-3.
8.1.5 Wall thickness will be calculated as required by the Pipe Specification. Wall
thickness will be calculated on the basis of information contained in the Pipe
Specification and in accordance with the design code. Pressure and temperature
conditions for these lines will be taken from the Line List and not the pressure and
temperature ratings shown in the Pipe Specification. (This would result in
pipework which may not meet the temperature / pressure rating throughout its
range).
The FW approved spreadsheet for calculating wall thickness is document 2730-
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8230-CA-10000, this should be updated according to pipe specification

requirements and printed as a final deliverable document. It can be found in
project folder Projectwise\EPCL 2730\01General\Piping\Piping engineering
documents\054pipstress\10-Wall Thickness Calculations.
The intention is to avoid excessively thick pipe and fittings which will lead to a stiff
and expensive piping system which will overload equipment nozzles. Vacuum
stability calculations for piping shall be in accordance with ASME V111 div 1
section UG-28.
8.1.6 Branch reinforcement calculations shall be performed where required, on an

Excel spreadsheet developed by the Piping Group, a copy of this spreadsheet
should be made and saved under a unique CA number, taken from the
calculation index.
Branch reinforcement will be to ASME B31.3, using wall thicknesses derived from
the Pipe Specification. Branch reinforcement shall be designed for full flange
rating with the exception of pipe and fitting thickness determined by calculation.
Branch reinforcement calculations shall be undertaken against Line List design
conditions for such cases.
8.1.7 Inform the Structural Group of any excessive loads on anchor/supports, platforms
or associated structures for inclusion in their overall design. Pipe anchors shall be
designed to take the maximum load which may be developed, on either side of
the anchor, minus one half of the accumulated load on the other side of the
anchor, and not the resultant load imposed at the anchor point. (See section
11.5)
8.1.8 Inform all Specialist Engineering Groups of piping loads at nozzles and support
points, in excess of the FW standard loads, found in Appendix 5, or
manufacturers own allowables, for inclusion in their overall design. Appropriate
blank Foster Wheeler nozzle load data sheets can be found in folder
Projectwise\EPCL 2730\01General\Piping\Piping engineering documents\\12-
Nozzle load data sheets.
8.1.9 Submit to the appropriate Vendor, if not agreed at order placement, loadings
imposed by the piping on equipment and rotating machines for his approval.
Manufacturers and FW specialist engineering groups should be urged to accept
the loads shown in Appendix 5 as a minimum.
8.1.10 Where data such as nozzle load sheets, spring supports etc are created for a
particular calculation, these files shall be stored in the appropriate directory. For
example, nozzle loads sheets are stored in the nozzle load directory. However in
addition to this; within the computer calculation directory (CA-xxxx, within CII
directory), shortcuts shall be placed to all of the relevant/appropriate
accompanying data, e.g. nozzle load sheets, such that it is easily accessible from
the calculation directory.
Similarly a hard copy stress calculation file shall be kept containing the same
details pertinent to each calculation.
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This arrangement gives full and easy access for engineers to review, edit and
understand each individual stress calculation in the absence of the originating
engineer. It also forms a comprehensive work history for each calculation.
8.1.11 The Authorised Stress Engineer shall sign all the piping general arrangement and
isometric drawings before construction issue, to signify that a flexibility check on
all lines has been carried out to his satisfaction and to the project requirements.
An Authorised Piping Engineer shall sign in his absence.
8.1.12 It is the responsibility of the Piping Engineer to monitor the piping design activities
on an on-going basis to ensure sufficient consideration is being made for piping
flexibility.
9 BELLOWS OR EXPANSION JOINTS
9.1 In cases where it is impractical to increase the flexibility of a pipeline to reduce the
stress range and/or terminal loads to an acceptable level the Stress Engineer may
specify the use of Bellows or Expansion Joints as a design solution.
9.2 It is necessary to obtain written confirmation for the use of Bellows or Expansion Joints
from the client prior to proceeding with the requisitions.
10 SPRING SUPPORTS AND SLIDE PLATES
10.1 Spring support units shall be detailed by FWEL and each one given a unique SH-
number. The engineer shall refer to document 2730-8230-IN-0004 - spring support
index and take out the next available SH-number. (Projectwise\EPCL
2730\01General\Piping\Piping engineering documents\054pipstress\01-Stress Indices)
On existing plant areas, the existing client numbering system shall be continued.
Where this occurs the stress engineer shall seek guidance from the lead stress
engineer in Reading.
10.2 The engineer should design the spring using the Witch hanger spring selection
program to include all required components. A summary of each spring should also be
to the Spring Summary Sheet. Both the Database and summary sheet are located in
the following folder: Projectwise\EPCL 2730\01General\Piping\Piping engineering
documents\\06-Spring Supports
10.3 A Witch Hanger Database has been created and stored in the relevant folder
(W:\Project\EPCL\2730\Gen\08Eng\054pipstress\06-Spring Supports) All spring
hangers shall be stored under their unique spring number within this database.
10.4 PTFE Slide units are permitted to reduce friction effects to strain sensitive equipment
and should be called up as using a unique SU number, taken from the slide unit index
found in folder Projectwise\EPCL 2730\01General\Piping\Piping engineering
documents\\054pipstress\13-Slide Units. Stress engineers should fill in the “Slide unit
summary sheet” (also found in this directory) stating slide unit number, size, operating
range and line/drawing number.
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10.5 In case where a spring support exists within the fire exposure region, (typically under
9.1m, see EDS-M-2) a fireproofed catch beam is required local to the spring hanger
(under the pipe)to act in an emergency case, where the spring support has failed
10.6 A sketch showing the Spring Support or Slide unit shall be made to show the
associated supporting steel work arrangement as well as the spring /slide itself. (i.e a
sketch showing: support beam PS-1a plus the spring hanger, the fireproofed catch
beam shall also be shown on the support sketch where applicable). Each spring
support sketch shall be saved in the appropriate folder. (Projectwise\EPCL
2730\01General\Piping\Piping engineering documents\\06-Spring Supports\Spring
Support Sketches)
11 PIPE SUPPORTS
11.1 Please refer to Pipe Support Specification document 2730-8230-SP-0003 (59B50).
11.2 It should be noted that due to the unusually large structural member sizes associated
with concrete racks. The length of piping required to place an effective Line stop will
be in excess of 400mm and in many cases up to 600mm. Care should be taken not to
overlook this.
11.3 Care should be taken when specifying the length of pipe shoes especially in systems
where high thermal growth is expected. Especially on the high pressure steam
systems where movement up to 250mm is permitted to reduce loop frequency.
11.4 Special pipes supports shall at all times be minimised, however where it is practical
and/or the use of standard pipe supports is not possible or will lead to onerous, unduly
large/complex arrangements, the use of special pipe supports is permitted.
Special pipe supports shall be identified on piping isometrics with a unique SPS
number, to be taken from the special pipe support Index document 2730-8230-IN-0005
located in the following directory Projectwise\EPCL 2730\01General\Piping\Piping
engineering documents\\054pipstress\01-Stress Indices.
Special pipe support drawings are to be stored electronically in the following location;
Projectwise\EPCL 2730\01General\Piping\Piping engineering
documents\\054pipstress\16-Special Pipe Supports. Where hand sketches are made,
these are to be scanned and renamed with the appropriate SPS number and stored in
the directory above.
This Index will then transcribed to follow the ENOC Plant wide special support
numbering system.
11.5 Where pipe supports are required and will, because of bearing capacity, be outside the
limits of the pipe support standard, the Stress Engineer shall transmit the appropriate
stress sketch and/or piping isometric including support requirements and bearing load
to the Lead Structural engineer for design. The appropriate inter-office transmittal shall
be used. (See point 13.1.3, for details of transmittal procedure)
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11.6 The table in attachment 19 shows load thresholds for civil design, above these loads
civil must be informed. A marked up drawing including loads or where more
appropriate a marked up drawing and accompanying table (see attachments 20) shall
be sent to civil using a transmittal. (See point 13.1.3, for details of transmittal
procedure)
11.7 Where possible support selection shall follow the typical support selection diagram in
the attachments section of the pipe support standard - 2730-8230-SP-0003 (59B50).
12 DRAWING DISTRIBUTION AND PROCEDURE
12.1 Drawings and documents required by the Stress Engineer normally include plot plans,
pipeway drawings, line lists, piping material specifications, basic engineering data,
piping system isometrics, vessel drawings, heat exchanger drawings, pump
arrangement drawings and piping general arrangement drawings where available.
13 STRESS CLEARANCE AND APPROVAL
13.1 Initial Stress Analysis
13.1.1 Line numbers identified on the stress critical line list require some form of stress
analysis/approval. Piping designers should forward isometrics as initially
extracted for detailed analysis and identify areas that require modification to the
piping system or its associated supports as necessary, the stress engineer shall
resolve a solution with the appropriate piping designer.
13.1.2 On completion of the stress analysis the stress engineer will produce two copies
of the marked up stress sketch. (A stress sketch can take the form of a marked
up piping isometric as shown in Appendix 16.) The original will be filed with the
stress calculations, one copy, stamped stress approved and dated, will be filed in
the stress section master sketch file and one copy stamped stress approved and
dated will be transmitted to the lead piping engineer together with a transmittal
note. See 11.5.5
13.1.3 The transmittal note will be a Word document; the file name will be taken from a
sequential list on the project directory. The transmittal note is to be addressed to
the Lead Piping Designer. The transmittal will list the stress sketch line numbers,
sheet numbers and revision. The transmittal should be copied to the Lead Piping
Engineer and a copy stored in the following directories; Projectwise\EPCL
2730\01General\Piping\Piping engineering documents\054 Pip stress\04-Stress
Transmittals. A paper copy shall also be filed in the stress transmittal file.
13.1.4 All stress sketches/stress isometrics are to be stored electronically in the

following directory; Projectwise\EPCL 2730\01General\Piping\Piping engineering
documents\054 pipe stress\05-Stress Sketches. Where hand sketches are made
they should be scanned and renamed with the appropriate isometric/calc number
and saved in the above directory. An electronic shortcut to the stress sketch shall
be placed in the appropriate calculation folder such that easy reference to the
drawing can be made from the Caesar II calculation folder.
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13.2 Final Stress Analysis
All final calculations shall be checked and approved under the following guidelines.
Category 1 calculations shall be checked in CEC as and when they are completed.
100% of these Calculations will be reviewed and approved by the lead stress
engineer in Reading after CEC checking.
Category 2 Calculations shall be checked and approved in CEC and a sample of 15%
of these will be reviewed in Reading.
A list of calculations required by Reading for final review and approval will be
generated during the isometric production phase of the job and details sent to all
engineers.
13.3 Isometrics
The Pipe Stress Section shall be supplied with one print of checked AFC isometrics
for comment and approval. Any stress comments shall be marked-up on the print
and the print stamped, signed and dated.
14 COMMENTS ON DRAWINGS
14.1 The stress engineer shall cover the following items when commenting on checked
isometrics or checked piping general arrangements:
14.1.1 Any additional flexibility required.
14.1.2 Any special or additional pipe supports which may be required for stress reasons
e.g. anchors, guides, slide plates, spring supports etc. Where special support
requirements are indicated as stress comments, the support designer must have
the support detail approved by the stress engineer.
14.1.3 Thermal movements must be shown at loops, bends and branches, to enable
suitable spacing is observed.
14.2 The original drawing with stress comments incorporated will be passed to the
Authorised Stress Engineer for review and signature before being issued for
construction.
14.3 If an isometric drawing issued for construction is revised in a manner which may affect
stress, the isometric shall be treated the same as a new isometric in order to obtain
stress approval.
15 DIFFERENTIAL SETTLEMENT
15.1 Differential settlement of, for example, discrete foundations and paving or equipment
such as tanks must be considered in piping stress analysis. Supports terminating at
grade may have to be of the adjustable type. Where possible piping such as valve
sets will be located adjacent to equipment or rack columns with the intention of
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incorporating pipe support foundation requirements with the equipment or rack

foundations. Consequently differential settlement should be minimal.
If it is difficult for the Civil Group to estimate differential settlement with any accuracy,
the approach to minimise differential settlement induced pipe stress shall be,
a) Route piping over piled/settled foundations foundations.
b) If a pipe is susceptible to differential settlement and the routing dictates the

pipe support must be away from a piled/settled foundation the Stress Section
should request a piled foundation from the Civil Group, for the particular
support
15.2 Any anticipated rack sway shall be obtained from the structural department.
15.3 As a first pass, in the absence of any additional information from the civil group, piping
shall be designed according to the figures given in appendix 14. As foundations
calculations progress the civil group shall be consulted on likely settlements
AFTER/DURING piping installation. Distinction should be made between settlement
that occurs under equipment and foundation loading, and has therefore passed by the
time piping installation takes place, and settlement that occurs after piping installation.
16 EARTHQUAKE LOADS
Earthquake should be considered for the site region as specified in appendix 13.
17 WIND LOADING
17.1 Site wind criteria are defined in appendix 13. In general wind loading must be
considered line by line. Pipe guides with increased gaps may be used for lines where
locked supports would create significant thermal loads. Lines below 10m elevation
need not have a wind loading analysis where the loadings are considered to be
insignificant.
18 DOCUMENTATION
18.1 General Filing and Housekeeping
It is important that filing and calculation management within the stress group is kept
orderly and transparently, such that any calculation can be picked up and continued
by another engineer and to make the checking process more streamlined.
• On beginning a new calculation the stress engineer will create a new number in
the stress calculation index.
• He will then note this calculation number into the stress critical line list along with
his initials and the date against all applicable lines to which the calculation is
pertinent.
• Having done this a new front sheet will be created from the template and as much
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information as is available will be entered in to the front sheet. This should be

saved electronically and also printed out to form the first few pages of the hard
copy working stress calculation file.
• The engineer should then take paper copies of all the relevant data he will need to
perform the calculation, this should also be placed within the working stress
calculation file for this calculation.
• At this point 10% can be recorded in the “Status” column of the stress critical line
list. (SCLL)
• It is Important that throughout the life of each calculation the engineer make notes
on a notes page updating the status of the calculation, recording any hold-ups/
problems or correspondence etc.
• Having generated the large part of the compulsory paper work, the engineer shall
now continue with analysis as is relevant, using Caesar or hand calculations as
described in this procedure, along with the other miscellaneous spreadsheets if
required.
• Status updates shall be entered into the SCLL as design progress and or vendor
information leads to advancement in the calculation.
• On completion, the entire hard copy stress dossier shall be kept as a record of the
calculation.
• In terms of Caesar files these shall be marked as final in the title page and moved
into the Final folder within the computer calculations folder and saved as the
calculation number. The hard copy stress master files will, after isometric
approval, be sent to reading for checking and archiving.
• All electronic documents linked to a calculation number shall be saved under the
calculation number in the relevant files. I.e. trunnion calculations go in the trunnion
calc folder.
18.2 Calculation Sheets
All calculations shall be headed by a 'Pipe Stress Calculation' front sheet. See
Appendices 4 & 6.
18.3 Computer Runs
Computer printouts will be available for review throughout the duration of the
project. Each printout shall be accompanied by further information as follows:-
18.3.1 The calculation "front-sheet" (an example of which is contained in Appendix 4)

must contain the following information:
(a) The Project title, client and contract number.

(b) Physical data used in the computer input.
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(c) Reference drawings and data.

(d) Calculation assumptions
18.3.2 Piping isometrics will include piping features such as branch type, support
type, node numbers etc.
18.3.3 These isometrics incorporate a series of tables that identify maximum generated
stresses and nozzle loads taken from the analysis output. These are tabulated
against allowable values. In addition, maximum displacements, forces and
moments along with their respective node number shall be noted within these
tables. Boundary initial displacements over 25mm shall also be noted.
18.3.4 Where spring supports are used the stress sketch must clearly show the spring
number, type, design load and movement. .
18.3.5 Other hand calculations and drawings of equipment particularly allowable nozzle
loading tables, axis orientation from equipment drawings,
calculated/approximated equipment growth/movement, requisitions, special pipe
supports and spring supports should also be included.
18.3.6 Calculations are to be numbered sequentially as determined by CA-number in

the following format; 2730-8230-CA-C001.01. This implies computer
calculation (CA-C) number 1 (001) revision 01. All other calculation items, i.e
nozzle load approval sheets, skirt expansion calcs, etc. shall be numbered
with the same number followed by a description of the item. E.g a Trunnion
calculation belonging to 2730-8230-CA-0001, will be labelled as follows:
2730-8230-CA-0001-Trunnion-01.xls
18.4 Hand Calculations
All documented hand calculations will be carried out on FW calculation

pads/Nomographs and spreadsheets as applicable, All Hand calculations shall
have front sheets as per Appendix 6. All Hand calculations shall be scanned and
saved into the 18-hand Calculations folder.
18.5 Pipe Supports
Spring Supports, specials and standard support data sheets shall be prepared, as
applicable. Refer to sections 10 and 11.
19 STRESS PROJECT FILING SCHEDULE
The following documents shall be maintained in the stress section:
19.1 File of master stress isometrics.
19.2 Sequential files for all calculations in calculation number order.
19.3 Equipment nozzle load data file.
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19.4 Schedule of Critical Lines.
This is an index of calculations for those lines considered to be critical by virtue of

size, temperature or connected equipment for which a formal stress analysis is
required. This provides a useful cross-reference between calculation numbers and
stress comments issued as a result of calculations as defined in Section 5.
19.5 Stress Comments
If any comments are issued or received, a copy of the letter / memo shall be retained
within the body of the affected stress analysis calculation(s). The file copy shall be
retained within the discipline central filing system. This copy shall be passed via the
Piping Engineer for his information when deemed necessary by the stress engineer.
All Stress comment are to be scanned and saved within the following directory;
Projectwise\EPCL 2730\01General\Piping\Piping engineering
documents\\054pipstress\15-Stress comments and correspondance\15.1-Stress
comments.
19.6 Stress Correspondence
Any Correspondence issued or received, shall be retained in the body of the affected
stress analysis calculation(s). An electronic copy shall also be stored within the
following directory; Projectwise\EPCL 2730\01General\Piping\Piping engineering
documents\\054pipstress\15-Stress comments and correspondance\15.2-Stress
correspondence.
Hand written/paper copy correspondence is to be scanned suitable renamed (to

include calculation number) and moved to the above directory.
20 STRESS PROGRESS
20.1 Status Reporting
Two columns are included in the Stress Critical Line List and these are used for
tracking progress through the stress analysis activity. Below are listed the 5 values
these should be entered into the “STATUS” column. The “STATUS REMARKS”
column shall be used to describe current issues with the calculation, such as
“HELD FOR VENDOR DATA”.
20.2 Status Descriptions and Values. The table below shows the 5 status categories.
Next to them are listed the required components of analysis which must all be
complete before this level of status can be reported.
STATUS DESCRIPTION
10% - Front sheets filled out with relevant line and equipment
names and numbers.
- Stress Calculation index and Critical line index filled in.
30% - Caesar model or hand calcs include:
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- Front sheets
- Line data
- Basic modelling/hand calcs in progress
- Engineers remarks concerning the calculation
- Problems/hold ups identified to lead stress engineer
60% - Caesar Model complete to latest isometric extraction (not

AFC).
- Preliminary analysis proves acceptable on the basis of
preliminary data.
- Initial structural and nozzle loads sent to appropriate
engineering groups where appropriate.
- Spring and PTFE slide plate datasheets created and
appropriate support sketches generated.
90% - Calculation Complete to final documentation – awaiting

final AFC isometric for final pass approval.
100% - Signed off AFC isometric and finalised calculation.

Printed filed and finished awaiting final check and
approval.
21 READING REVIEW AND CEC VISITS
21.1 Projectwise filing.
To facilitate simple review of calculations and progress monitoring the following procedure
shall be adopted by all stress engineers:
21.1.1 Caesar master files
Projectwise shall be used for storing master calculation files.
A new folder in projectwise shall be created for each calculation in the appropriate
area of projectwise:
pwdesc:\\PW_2730\Documents\EPCL 2730\01 General\Piping\Piping Engineering
Documents\054-Pipe Stress\02-Ceasar II Calculations\CA-XXXX\
At the 30% point described in section 20, the master Caesar II file shall be saved in
projectwise as CA-XXXX_30 in the appropriate unit/folder area, as shown above.
This calculation will then be copied out of projectwise and worked on within the
stress engineers own PC environment. When it reaches 60% it will stored within
projectwise as CA-XXXX_60.
After further progress it will then be saved into projectwise at 90%.
Once the AFC isometric has been received, all stress work completed and
checked, the final revision will be saved at CA-XXXX_F1.
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This will leave a trail of versions of the calculations for review at any time and a
backup to progress reporting. Once the calculation has been reviewed and
accepted in reading only the F1 revision will kept for archiving purposes.
21.1.2 Supporting documents
The appropriate front sheet shall also be added to:

pwdesc:\\PW_2730\Documents\EPCL 2730\01 General\Piping\Piping Engineering
Documents\054-Pipe Stress\03-Front Sheets.
This will be done at the same phases as described above.
All other relevant documentation and supporting calcs as described within this
procedure shall be placed in the relevant projectwise locations as and when they
are available.
21.2 Initial Calculation Review
The review of stress analysis during and at the end of the project is of extreme
importance to ensure quality standards and acceptable basis for design are
achieved. This is heightened by working across two execution centres.
There will be an initial review of the first calculations being done by the CEC office
in order to ensure that a common understanding across analysis and stress
deliverables has been achieved. The content and scale of this review shall be
decided on by the Lead stress Engineer in Reading, but this will typically consist of
5 to 10 calculations at 60% status.
Having completed this review in Reading there will be a visit to CEC to speak of the
issues raised, discuss any improvements or areas of concern and further promote
good communication.
21.3 Continued Calculation review
Additional reviews will be on going throughout the project according to analysis

progress.
21.4 Review Information
In order for effective and concise reviews to be undertaken in Reading, CEC will
furnish the Reading office with the following data for review:
All CII calculation files (input and results)

Any supporting spreadsheet calculations
All vendor data used for the calculation
Isometric extractions or sketches
(Essentially all files and data pertinent to the calculation).
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The method of transference shall be discussed at review time to establish the most
time effective and appropriate method of transfer.
NOTE: CEC should not send large input and result printouts through the internal
mail for review before consulting with the Lead stress engineer in Reading.
21.5 CEC Visits
The lead stress engineer will visit CEC on a program of visits to ensure smooth
progress of stress analysis, communication and solving of problems and issues not
resolved through email, net-meeting and telephone, to ensure particular stress
analysis deadlines can be met, and continued team building.
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APPENDIX 1
EXTENT OF STRESS ANALYSIS
Piping connected to equipment other than

Rotating Machinery, Air Fin Coolers and Tanks
∆T °C
2
400
∆T ≥ 330 °C
∆T < 330 °C
1
300
∆T ≥ 230 °C
∆T < 230 °C
200 ∆T ≥ 180 °C
∆T < 180 °C
3
2
∆T > 80 °C 100
∆T ≤ 80 °C ∆T > 40 °C
∆T ≤ 40 °C
0
0 2 4 6 8 10 12 14 16 18 20 22 24 & ABOVE
LEGEND: Nominal Pipe Size (Inches)
1 Indicates computer analysis required
2 Indicates chart/nomograph analysis is adequate
3 Indicates visual inspection is adequate
Notes
1. 1) indicates computer analysis required.

2) indicates Chart/Nomograph analysis is adequate.
3) indicates visual inspection is adequate.
2. The above chart is to be used as a guide and must be read in conjunction with
section 6 of this procedure.
3. Chart is based on standard wall thickness
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APPENDIX 2
Piping connected to Rotating Machinery

or Air Fin Coolers
∆T °C
400
2
300 1
∆T ≥ 180 °C 200
∆T < 180 °C
2
100 ∆T > 80 °C
∆T ≤ 80 °C
3 2
0
0 2 4 6 8 10 12 14 16 18 20 22 24 & ABOVE
LEGEND: Nominal Pipe Size (Inches)
Notes

3. Chart is based on standard wall thickness.
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APPENDIX 3
Piping connected to Tanks

(No Flexible Joints)
∆T °C
400
1
300
∆T ≥ 230 °C
∆T < 230 °C 200 ∆T ≥ 180 °C

∆T < 180 °C
2
100 3 ∆T > 80 °C
∆T ≤ 80 °C
0
0 2 4 6 8 10 12 14 16 18 20 22 24 & ABOVE
Nominal Pipe Size (Inches)

LEGEND:
Notes

3. Chart is based on standard wall thickness.
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APPENDIX 4
COMPUTER CALCULATION FRONT SHEETS
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APPENDIX 5
FW ALLOWABLE LOADS EVALUATION TABLE
EQUIPMENT TYPE ALLOWABLE NOZZLE LOADS
PUMPS
1) Vendor information will be reviewed for acceptability
when available.
2) Pumps other than those above and including metering
pumps - minimum requirements API.610. Vendor
information will be reviewed for acceptability when
available.
VESSELS Refer to appendix 7.
(INCLUDING HEAT EXCHANGERS, AIRFIN COOLERS, STORAGE TANKS (subject to

vendors multiple, where applicable))
CENTRIFUGAL COMPRESSORS Refer to Appendix 18 and manufacturer’s allowables
STEAM TURBINES Refer to Appendix 17 and manufacturer’s allowables
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APPENDIX 6
STANDARD CALCULATION FRONT SHEETS FOR DOCUMENTED
HAND CALCULATIONS
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APPENDIX 7
FW ALLOWABLE NOZZLE LOADS
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APPENDIX 8
MAXIMUM RECOMMENDED SPANS – Carbon Steel
Pipe Wall Insulation Maximum Span (m)

Size Thicknes Thicknes
s s
NPS mm mm Case ‘A’ Case ‘B’ Case ‘C’ Case ‘D’
0.5 3.7 50 2.7 2.4 2 1.7

0.75 3.9 63 3.0 2.7 2.4 2.0
1 4.5 63 3.4 3 2.7 2.5
1.5 5.1 75 4.1 3.7 3.3 3.2
2 3.91 75 4.7 4.3 3.7 3.5
3 5.49 75 5.8 5.3 4.9 4.7
4 6.02 75 6.5 6.0 5.8 5.4
6 7.11 75 8.0 7.3 6.9 6.6
8 7.04 75 9.1 8.2 7.7 7.4
10 7.8 75 10.2 9.5 8.0 8.2
12 8.38 75 11.2 10.3 7.2 6.9
14 9.52 75 12.0 11.2 8.2 7.4
16* 9.52 75 12.5 11.7 10.5 10.0
18* 9.52 75 11.9 12.5 10.9 10.3
20* 9.52 75 14.0 11.9 11.0 10.6
24* 9.52 75 15.4 14.0 10.2 9.6
30** 9.52 75 17.2 15.4 11.9 11.5
36** 9.52 75 18.9 17.2 12.4 11.8
42** 9.52 75 20.4 18.9 12.6 12.0
48** 9.52 75 21.8 20.4 12.8 12.2
Design Basis
1. Maximum deflection at midspan is 6mm, due to total self weight or a stress limit of 25
N/mm², due to total self-weight will be considered whichever allows the lesser
span. Total self-weight includes process contents and insulation.
2. Empty pipe not insulated (Case 'A'), insulated pipe filled with water (Case 'B'), 3mm
corrosion allowance.
3. * Denotes pad of pipe thickness required.

* Clamps, where used, replace pads.
** Denotes use support S15, S16 OR S17.
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APPENDIX 9
MAXIMUM RECOMMENDED SPANS – Stainless Steel, hastalloy.
Pipe Wall Insulation Maximum Span (m)

Size Thicknes Thicknes
s s
Case ‘A’ Case ‘B Case ‘C Case ‘D’
NPS mm mm
0.5 3.73 50 2.7 2.4 2.0 1.7
0.75 3.91 63 3.0 2.7 2.4 2.0
1 4.55 63 3.4 3.0 2.8 2.5
1.5 5.08 75 4.1 3.7 3.4 3.2
2 5.54 75 4.7 4.2 4.0 3.8
3 3.05 75 5.8 5.3 4.4 4.1
4 3.05 75 6.6 6.0 5.2 4.6
6 3.4 75 8.1 7.4 6.0 5.6
*8 3.76 75 9.2 8.6 6.8 6.3
*10 4.19 75 10.3 9.5 6.2 6.9
*12 4.57 75 8.2 7.7 7.6 7.4
*14 4.78 75 8.5 8.1 7.8 7.7
*16 4.78 75 9.9 9.4 8.2 7.9
*18 4.78 75 8.3 8.0 7.6 7.3
**20 5.54 75 14.1 13.5 9.0 8.7
**24 6.35 75 15.4 14.1 9.2 9.5
**30 9.52 75 17.2 15.4 11.7 11.5
**36 9.52 75 18.9 17.2 12.0 11.8
**42 9.52 75 20.4 18.9 12.4 12.0
**48 10.52 75 21.8 20.4 12.6 12.2
Design Basis
1. Maximum deflection at mid-span is 6mm, due to total self weight or a stress limit of 25
N/mm², due to total self weight will be considered, whichever allows the lesser
span. Total self-weight includes process contents and insulation.
2. Empty pipe not insulated (Case 'A'), insulated pipe filled with water (Case 'B').
Corrosion allowance as specified.
3. * Denotes, pad of pipe thickness required.

* Clamps, where used, replace pads.
** Denotes, use support size S15, S16 or S17.
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APPENDIX 10
EXPANSION COEFFICIENT VALUES FOR

A312 TP304L STAINLESS STEEL
DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M
-10 -0.32 100 0.92 200 2.2 300 3.61 400 5.16 500 6.81 600 8.49 700 10.13
-5 -0.27 105 0.98 205 2.27 305 3.69 405 5.24 505 6.89 605 8.57 705 10.21
0 -0.22 110 1.04 210 2.34 310 3.76 410 5.32 510 6.98 610 8.65 710 10.29
5 -0.16 115 1.11 215 2.41 315 3.84 415 5.4 515 7.06 615 8.73 715 10.38
10 -0.11 120 1.17 220 2.48 320 3.91 420 5.49 520 7.14 620 8.81 720 10.46
15 -0.05 125 1.23 225 2.54 325 3.99 425 5.57 525 7.22 625 8.89 725 10.54
20 0 130 1.29 230 2.61 330 4.06 430 5.65 530 7.3 630 8.97 730 10.63
25 0.05 135 1.35 235 2.68 335 4.14 435 5.74 535 7.38 635 9.04 735 10.71
30 0.11 140 1.42 240 2.75 340 4.22 440 5.82 540 7.47 640 9.13 740 10.8
35 0.17 145 1.48 245 2.82 345 4.29 445 5.9 545 7.55 645 9.21 745 10.88
40 0.22 150 1.55 250 2.89 350 4.37 450 5.99 550 7.64 650 9.29 750 10.97
45 0.28 155 1.61 255 2.96 355 4.45 455 6.07 555 7.72 655 9.37
50 0.33 160 1.67 260 3.03 360 4.52 460 6.15 560 7.81 660 9.45
55 0.39 165 1.74 265 3.1 365 4.6 465 6.23 565 7.9 665 9.54
60 0.45 170 1.8 270 3.18 370 4.68 470 6.31 570 7.98 670 9.62
65 0.51 175 1.87 275 3.25 375 4.76 475 6.4 575 8.06 675 9.71
70 0.56 180 1.94 280 3.32 380 4.84 480 6.48 580 8.15 680 9.79
75 0.62 185 2 285 3.39 385 4.92 485 6.57 585 8.23 685 9.88
80 0.68 190 2.07 290 3.46 390 5 490 6.65 590 8.32 690 9.96
85 0.74 195 2.14 295 3.54 395 5.08 495 6.73 595 8.41 695 10.04
90 0.8
95 0.86
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APPENDIX 10 (cont’d)
EXPANSION COEFFICIENTS FOR

A312 TP321 STAINLESS STEEL
DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M
-10 -0.49 100 1.35 200 3.1 300 4.93 400 6.83 500 8.81 600 10.86 700 12.9 800 15.04
-5 -0.41 105 1.43 205 3.19 305 5.03 405 6.93 505 8.92 605 10.96 705 13 805 15.16
0 -0.33 110 1.52 210 3.28 310 5.12 410 7.03 510 9.02 610 11.06 710 13.1 810 15.29
5 -0.24 115 1.61 215 3.37 315 5.21 415 7.13 515 9.12 615 11.17 715 13.2 815 15.41
10 -0.16 120 1.69 220 3.46 320 5.31 420 7.23 520 9.23 620 11.27 720 13.31
15 -0.08 125 1.78 225 3.56 325 5.4 425 7.32 525 9.33 625 11.38 725 13.41
20 0 130 1.87 230 3.65 330 5.5 430 7.42 530 9.43 630 11.48 730 13.51
25 0.08 135 1.95 235 3.74 335 5.59 435 7.52 535 9.53 635 11.58 735 13.61
30 0.16 140 2.04 240 3.83 340 5.68 440 7.62 540 9.64 640 11.68 740 13.71
35 0.25 145 2.13 245 3.92 345 5.78 445 7.72 545 9.74 645 11.78 745 13.82
40 0.33 150 2.22 250 4.01 350 5.87 450 7.82 550 9.84 650 11.89 750 13.92
45 0.41 155 2.3 255 4.1 355 5.97 455 7.92 555 9.94 655 11.99 755 14.02
50 0.5 160 2.39 260 4.19 360 6.06 460 8.01 560 10.04 660 12.09 760 14.12
55 0.58 165 2.48 265 4.28 365 6.15 465 8.11 565 10.14 665 12.19 765 14.23
60 0.66 170 2.57 270 4.37 370 6.25 470 8.21 570 10.25 670 12.29 770 14.35
65 0.75 175 2.66 275 4.47 375 6.34 475 8.31 575 10.35 675 12.39 775 14.46
70 0.83 180 2.75 280 4.56 380 6.44 480 8.41 580 10.45 680 12.49 780 14.58
75 0.92 185 2.84 285 4.65 385 6.54 485 8.51 585 10.55 685 12.59 785 14.7
80 1 190 2.92 290 4.75 390 6.64 490 8.61 590 10.66 690 12.7 790 14.81
85 1.09 195 3.01 295 4.84 395 6.74 495 8.71 595 10.76 695 12.8 795 14.93
90 1.18
95 1.26
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APPENDIX 11
EXPANSION COEFFICIENTS FOR

API-5L Gr B CARBON STEEL
DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M DEG C mm/M
-10 -0.32 100 0.92 200 2.2 300 3.61 400 5.16 500 6.81 600 8.49 700 10.13
-5 -0.27 105 0.98 205 2.27 305 3.69 405 5.24 505 6.89 605 8.57 705 10.21
0 -0.22 110 1.04 210 2.34 310 3.76 410 5.32 510 6.98 610 8.65 710 10.29
5 -0.16 115 1.11 215 2.41 315 3.84 415 5.4 515 7.06 615 8.73 715 10.38
10 -0.11 120 1.17 220 2.48 320 3.91 420 5.49 520 7.14 620 8.81 720 10.46
15 -0.05 125 1.23 225 2.54 325 3.99 425 5.57 525 7.22 625 8.89 725 10.54
20 0 130 1.29 230 2.61 330 4.06 430 5.65 530 7.3 630 8.97 730 10.63
25 0.05 135 1.35 235 2.68 335 4.14 435 5.74 535 7.38 635 9.04 735 10.71
30 0.11 140 1.42 240 2.75 340 4.22 440 5.82 540 7.47 640 9.13 740 10.8
35 0.17 145 1.48 245 2.82 345 4.29 445 5.9 545 7.55 645 9.21 745 10.88
40 0.22 150 1.55 250 2.89 350 4.37 450 5.99 550 7.64 650 9.29 750 10.97
45 0.28 155 1.61 255 2.96 355 4.45 455 6.07 555 7.72 655 9.37
50 0.33 160 1.67 260 3.03 360 4.52 460 6.15 560 7.81 660 9.45
55 0.39 165 1.74 265 3.1 365 4.6 465 6.23 565 7.9 665 9.54
60 0.45 170 1.8 270 3.18 370 4.68 470 6.31 570 7.98 670 9.62
65 0.51 175 1.87 275 3.25 375 4.76 475 6.4 575 8.06 675 9.71
70 0.56 180 1.94 280 3.32 380 4.84 480 6.48 580 8.15 680 9.79
75 0.62 185 2 285 3.39 385 4.92 485 6.57 585 8.23 685 9.88
80 0.68 190 2.07 290 3.46 390 5 490 6.65 590 8.32 690 9.96
85 0.74 195 2.14 295 3.54 395 5.08 495 6.73 595 8.41 695 10.04
90 0.8
95 0.86
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APPENDIX 12
CAESAR II CALCULATION SET UP
Including - SIF Directives
- Unit file MM.FIL
- Geometry directives
CAESAR II CALCULATION SETUP
CONNECT GEOMETRY THRU CNODES = YES

MIN ALLOWED BEND ANGLE = 5.00000
MAX ALLOWED BEND ANGLE = 95.0000
BEND LENGTH ATTACHMENT PERCENT = 1.00000
MIN ANGLE TO ADJACENT BEND PT = 5.00000
LOOP CLOSURE TOLERANCE = 25.4000 mm.
THERMAL BOWING HORZ TOLERANCE = 0.100000E-03
AUTO NODE NUMBER INCREMENT = 10.0000
Z AXIS UP = NO
USE PRESSURE STIFFENING = DEFAULT
ALPHA TOLERANCE = 0.500000E-01
RESLD-FORCE = NO
HGR DEF RESWGT STIF = 0.175127E+13 N./cm.
DECOMP SNG TOL = 0.100000E+11
BEND AXIAL SHAPE = YES
FRICT STIF = 0.175127E+07 N./cm.
FRICT NORM FORCE VAR = 0.150000
FRICT ANGLE VAR = 15.0000
FRICT SLIDE MULT = 1.00000
ROD TOLERANCE = 1.00000
ROD INC = 2.00000
INCORE NUMERICAL CHECK = NO
OUTCORE NUMERICAL CHECK = NO
DEFAULT TRANS RESTRAINT STIFF = 0.175127E+13 N./cm.
DEFAULT ROT RESTRAINT STIFF = 0.112985E+12 N.m./deg
IGNORE SPRING HANGER STIFFNESS = NO
MISSING MASS ZPA = EXTRACTED
MIN WALL MILL TOLERANCE = 12.5000
WRC-107 VERSION = MAR 79 1B1/2B1
WRC-107 INTERPOLATION = LAST VALUE
DEFAULT AMBIENT TEMPERATURE = 10.0000 C
BOURDON PRESSURE = NONE
COEFFICIENT OF FRICTION (MU) = 0.000000
INCLUDE SPRG STIF IN HGR OPE = NO
REDUCED INTERSECTION = B31.1(POST1980)
USE WRC329 = NO
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NO REDUCED SIF FOR RFT AND WLT = NO

B31.1 REDUCED Z FIX = YES
CLASS 1 BRANCH FLEX = NO
ALL STRESS CASES CORRODED = NO
ADD TORSION IN SL STRESS = DEFAULT
ADD F/A IN STRESS = DEFAULT
OCCASIONAL LOAD FACTOR = 0.000000
DEFAULT CODE = B31.3
B31.3 SUS CASE SIF FACTOR = 1.00000
ALLOW USERS BEND SIF = YES
USE SCHNEIDER = NO
YIELD CRITERION STRESS = MAX 3D SHEAR
USE PD/4T = NO
BASE HOOP STRESS ON ? = ID
APPLY B318 NOTE2 = NO
LIBERAL EXPANSION ALLOWABLE = YES
STRESS STIFFENING DUETO PRESSURE = NONE
B31.3 WELDING/CONTOUR TEE ISB16.9 = NO
PRESSURE VARIATION IN EXP CASE = DEFAULT
USE FRP SIF = YES
USE FRP FLEX = YES
BS 7159 Pressure Stiffening = Design Strain
FRP Property Data File = CAESAR.FRP
FRP Emod (axial) = 0.220632E+08 KPa
FRP Ratio Gmod/Emod (axial) = 0.250000
FRP Ea/Eh*Vh/a = 0.152727
FRP Laminate Type = THREE
FRP Alpha = 21.6000 C
FRP Density = 0.166079E-02 kg./cu.cm.
EXCLUDE f2 FROM UKOOA BENDING = NO
EXECUTION CONTROL PARAMETERS
Rigid/ExpJt Print Flag ..... 1.000

Bourdon Option ............. .000
Loop Closure Flag .......... .000
Thermal Bowing Delta Temp .. .000 C
Liberal Allowable Flag ..... 1.000
Uniform Load Option ........ 1.000
Pressure Stiffening Option . .000
Ambient Temperature ........ 1.00000 C
Plastic (FRP) Alpha ........ 21.600
Plastic (FRP) GMOD/EMODa ... .250
Plastic (FRP) Laminate Type. 3.000
Eqn Optimizer .............. .000
Node Selection ............. .000
Eqn Ordering ............... .000
Collins .................... .000
Degree Determination ....... .000
User Eqn Control ........... .000
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CAESAR II, FRP PIPE PROPERTIES
USE_FRP_SIF = YES (default)

USE_FRP_FLEX = YES (default)
BS_7159_Pressure_Stiffening = Design_Strain (default)
FRP_Property_Data_File = CAESAR.FRP * (default)
FRP_Emod_(axial) = 0.2206322E+08 (default)
FRP_Ratio_Gmod/Emod_(axial) = 0.25000000 (default)
FRP_Ea/Eh*Vh/a = 0.15272720 (default)
FRP_Laminate_Type = THREE (default)
FRP_Alpha = 21.6 (default)
FRP_Density = 0.001660794 (default)
CAESAR II, DATA BASE DIRECTIVES
STRCT_DBASE = AISC89.BIN (default)

VALVE_&_FLANGE = CADWORX.VHD (default)
EXPANSION_JT_DBASE = PATHWAY.JHD (default)
PIPING_SIZE_SPECIFICATION = ANSI (default)
DEFAULT_SPRING_HANGER_TABLE = 16 (default)
SYSTEM_DIRECTORY_NAME = SYSTEM (default)
UNITS_FILE_NAME = MM.FIL
UNITS FILE: MM.FIL
QUANTITY INTERNAL UNITS CONSTANT USER UNITS
Length inches x 25.400 = mm.

Force pounds x 4.4480 = N.
Mass (dynamics) pounds x 0.45359 = Kg.
Moments (input) inch-pounds x 0.11298 = N.m.
Moments (output) inch-pounds x 0.11298 = N.m.
Stress lbs./sq.in. x 6.8948 = KPa
Temp. Scale degrees F. x 0.55560 = C
Pressure psig x 6.8948 = KPa
Elastic Modulus lbs./sq.in. x 6.8948 = KPa
Pipe Density lbs./cu.in. x 0.27680E-01 = kg./cu.cm.
Insulation Dens. lbs./cu.in. x 0.27680E-01 = kg./cu.cm.
Fluid Density lbs./cu.in. x 0.27680E-01 = kg./cu.cm.
Transl. Stiff. lbs./in. x 1.7512 = N./cm.
Rotational Stiff in.lb./deg. x 0.11298 = N.m./deg
Uniform Load lb./in. x 1.7512 = N./cm.
G Load g`s x 1.0000 = g's
Wind Load lbs./sq.in. x 6.8948 = KPa
Elevation inches x 0.25400E-01 = m.
Compound Length inches x 25.400 = mm.
Diameter inches x 25.400 = mm.
Wall Thickness inches x 25.400 = mm.
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APPENDIX 13
SITE DESIGN CONDITIONS AND GOVERNING CODES
JEBEL ALI: AMBIENT TEMPRATURE: 25°C

Dudai, UAE (base on BEDD Sheet)
MINIMUM DESIGN TEMP 1 °C

(base on BEDD Sheet)
WIND LOADS: BS6399 Part 2 (Design)

ASCE 7 (Caesar II Wind Profile)
EARTHQUAKE: UBC 1997
SETTLEMENT: SEE APPENDIX 14
PIPING DESIGN CODE: ASME B31.3 2002 Edition
WIND DESIGN LOADS
Wind design is required for all lines 14” and larger AND above 10m in elevation. Where
wind is applicable it will usually be significantly more onerous that earthquake design.
Basic Engineering Design Datasheet 01-A-10010 from ENOC States Design Winds
speed of 160Km/Hr for 3 second gusts. Mean hourly wind speed is 87km/hr.
This is translated to appropriate units for Caesar II of 24.17 m/sec.
Prevailing wind direction as given in the BEDD is true west, however in the case of
Caesar analysis add the wind in the four global axis directions.
Therefore four wind cases will be entered in +X,-X,+Z and –Z.

Basic wind speed shall be entered as 24.17 m/sec.
The ASCE#7 wind parameters shall be used within Caesar II for stress analysis on this
job.
EARTHQUAKE DESIGN CRITERION
Seismic data, as supplied by Dames & Moore Group Company, Report No. 35515-001-
345 (February 3 1997).
Design Seismic loading shall be as follows:

Designated Earthquake Zone: 1
Importance Factor: 1.25
Site Coefficient: 1.2
Horizontal Seismic Coefficient 0.075g
Vertical Seismic Coefficient 0.040g
Therefore for seismic design within Caesar the above, bold, uniform loads shall be
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entered in the model as an Earthquake case analysed.
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APPENDIX 14
SPECIAL DIFFERENTIAL SETTLEMENT CONSIDERATIONS
Differential settlement must be taken into account in piping stress analysis when the
following values are exceeded:
Pumps to pipe racks 5 mm

Pumps to drums and storage tanks 10 mm
Pumps to shell and tube exchangers 10 mm
Pumps to columns 5 mm
Turbines to pipe racks 5 mm
Shell and tube exchangers to pipe racks 10 mm
Shell and tube exchangers to drums 10 mm
Shell and tube exchangers to columns 10 mm
Columns to pipe racks 15 mm
Columns to air cooler exchangers 15 mm
Where it is necessary to design for greater settlements, the initial amount occurring during
construction and testing may be ignored. In such cases it should be clearly noted that piping
connections must be made after hydrostatic testing.
It is the responsibility of the civil group to inform the piping group where settlement figures are
greater than the table given above. Piping design shall proceed on the basis of settlement
not exceeding the above table until additional information is forthcoming from the civil
Engineering group.
Piping at Storage Tanks
Differential settlement at tanks is particularly important and data must be obtained prior to the
design of piping on the following:
1. Amount of settlement.
2. The period of time over which settlement occurs.
3. Amount of settlement and recovery that occurs following construction

and hydrotest.
When large storage tanks are filled, the walls bulge and nozzles located in the lower course
are rotated downwards. Any restraint to this rotation by the stiffness of the connected piping
will cause a stress in the tank shell, which must be limited to values defined by the Vessel
Engineer. It is imperative for design to proceed that the Vessel Engineer shall be consulted
during the design of all lines to tanks to ensure adequate provisions are made.
The combined effects of settlement and nozzle rotation may suggest supporting the piping on
springs. However, before pursuing this course a check should be made on the possibility of
the line becoming drained during a normal operation cycle. If this should occur the supporting
springs may impose an excessive upward force on the tank nozzle. Where the line can only
be drained when the tank is out of service, instructions shall be issued for the springs to be
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locked before draining.
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APPENDIX 15
STRESS NOMOGRAPH AND LOOP SIZING CHART
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Nomograph scanned from:

Kannappan, S. (1986),
Introduction to Pipe Stress Analysis,
Wiley, USA.
0001.F2.DOC
FOSTER WHEELER
PIPING ENGINEERING
DSN:
TECHNICAL NOTES
APPENDIX 16
0001.F2.DOC
FOSTER WHEELER
PIPING ENGINEERING
DSN:
TECHNICAL NOTES
APPENDIX 17
NOZZLE LOAD EVALUATION AT STEAM TURBINES
0001.F2.DOC
FOSTER WHEELER
PIPING ENGINEERING
DSN:
TECHNICAL NOTES
CONTRACT NO: 1-14-2730 CALCULATION NO: 2730-8230-CA-T0000

CLIENT: ENOC SAFETY CALCULATION: YES
PROJECT: NAPHTHA HYDROTREATER COMPUTER PROGRAM: -
REFORMER PROJECT CALCULATION CLASS : 1
DISCIPLINE: PIPING ENGINEERING PAGE 1 of 1

TURBINE NOZZLE LOADING BASED ON SM 23-1991 edition
Area/Unit Number: Date: SM-23 Mulitple
Inlet Line Number: Engineer:
Ext raction Line Number: Revision: 1
Exhaust Line Number:
Fr = RESULTANT FORCE ON NOZZLE IN NEWTON Passed or Failed

Mr = RESULTANT MOMENT ON NOZZLE IN NEWTON-METER
De = NOMINAL BORE OF PIPING UPTO 8"
FOR PIPE SIZES LARGER THAN 8": PASSED
16 + N . B
De =
3
Fc = COMBINED RESULTANT OF ALL FORCE RESOLVED AT THE CENTRELINES OF
THE EXHAUST CONNECTION.
Mc = COMBINED RESULTANT OF ALL MOMENTS RESOLVED AT THE CENTRELINES
OF THE EXHAUST CONNECTION.
N.B = NOMINAL BORE IN INCHES
d = INSIDE NOZZLE DIAMETER IN INCHES
Dc = d 2
inlet +d 2
extr . + d 2
exhaust For Dc upto 9" 8.94
18 + d 2
+d 2
extr . + d 2
Dc =
inlet exhaust
3 For Dc Above 9"

N.B d
Inlet Nominal Bore = 4 4 De = 4
Extract Nominal Bore = De = Note: if no extract line is present leave blank
Exhaust Nominal Bore = 8 8 De = 8 Dc = 8.94
Not e: User entry required in yellow boxes, calculat ion results in blue boxes.
Fx Fy Fz Mx My Mz
SUSTAINED (FOR REFERENCE) Fr = Fx2 + Fy2 + Fz 2 = 571.61
INLET
-15.00 Mr = Mx + My + Mz =
2 2 2
SUSTAINED + THERMAL 178.00 -445.00 -311.50 158.66 70.66
174.33
0.67Fr + 0.74Mr =
=
TRANSFERRED TO 511.98
1 178.00 -445.00 -311.50 271.30 203.50 -163.00
EXHAUST 511.98 500 De ≤ PASSED
SUSTAINED (FOR REFERENCE)
EXTRACT
2 2 2
Fr = Fx + Fy + Fz = 0.00
SUSTAINED + THERMAL Mr = Mx + My + Mz =
2 2 2
0.00
TRANSFERRED TO 0.67Fr + 0.74Mr = 0.00
2 EXHAUST = 0.00 ≤ 500 De PASSED
Fr = Fx2 + Fy2 + Fz2 =
EXHAUST
SUSTAINED
1455.63
(FOR REFERENCE)
Mr = Mx2 + My2 + Mz2 = 922.47
0.67Fr + 0.74Mr = 1657.90
3 SUSTAINED + THERMAL -489.50 -1112.50 801.00 678.00 407.00 475.00
= 1657.90 ≤ 500 De PASSED
Sum of 1,2,3, -311.5 -1557.5 489.5 949.3 610.5 312.0
Fc = Fx + Fy + Fz2 =
2 2 1662.06
Multiply the above forces by
-70.1 -350.4 110.1 702.5 451.8 230.9
0.225 and moments by 0.74
Mc = Mx2 + My2 + Mz2 = 1170.99
SM-23 Allowables -> 447.2 1118.0 894.4 2236.1 1118.0 1118.0
0.45Fc + 0.74Mc = 1614.46
Multiple ->
1 50 Dc 125 Dc 100 Dc 250 Dc 125 Dc 125 Dc = 1614.46 ≤ 250 Dc PASSED
0001.F2.DOC
FOSTER WHEELER
PIPING ENGINEERING
DSN:
TECHNICAL NOTES
APPENDIX 18
NOZZLE LOAD EVALUATION AT CENTRIFUGAL COMPRESSORS
CONTRACT NO: 1-14-2730 CALCULATION NO: 2730-8230-CA-0000

CLIENT: ENOC SAFETY CALCULATION: YES
PROJECT: NAPHTHA HYDROTREATER COMPUTER PROGRAM: -
REFORMER PROJECT CALCULATION CLASS : 1
DISCIPLINE: PIPING ENGINEERING PAGE 1 of 1

COMPRESSOR NOZZLE LOADING BASED ON SM 23-1991 edition
Area/Unit Number: Date: SM-23 Mulitple
Inlet Line Number: Engineer:
Other Line Number: Revision: 1
Outlet Line Number:
Fr = RESULTANT FORCE ON NOZZLE IN NEWTON Passed or Failed

Mr = RESULTANT MOMENT ON NOZZLE IN NEWTON-METER
De = NOMINAL BORE OF PIPING UPTO 8"
FOR PIPE SIZES LARGER THAN 8": PASSED
16 + N . B
De =
3
Fc = COMBINED RESULTANT OF ALL FORCE RESOLVED AT THE CENTRELINES OF
THE OUTLET CONNECTION.
Mc = COMBINED RESULTANT OF ALL MOMENTS RESOLVED AT THE CENTRELINES
OF THE OUTLET CONNECTION.
N.B = NOMINAL BORE IN INCHES
d = INSIDE NOZZLE DIAMETER IN INCHES
Dc = d 2
inlet +d 2
other + d 2
outlet For Dc upto 9" 8.94
18 + d 2
+d 2
+ d 2
Dc =
inlet other outlet
3 For Dc Above 9"

N.B d
Inlet Nominal Bore = 4 4 De = 4
Other Nominal Bore = De = Note: if no other line is present leave blank
Outlet Nominal Bore = 8 8 De = 8 Dc = 8.94
Note: User entry required in yellow boxes, calculation result s in blue boxes.
Fx Fy Fz Mx My Mz
SUSTAINED (FOR REFERENCE) Fr = Fx2 + Fy2 + Fz 2 = 571.61
INLET
-15.00 Mr = Mx + My + Mz =
2 2 2
SUSTAINED + THERMAL 178.00 -445.00 -311.50 158.66 70.66
174.33
0.67Fr + 0.74Mr =
=
TRANSFERRED TO 511.98
1 178.00 -445.00 -311.50 271.30 203.50 -163.00
OUTLET 511.98 500 De ≤ PASSED
SUSTAINED (FOR REFERENCE)
EXTRACT
2 2 2
Fr = Fx + Fy + Fz = 0.00
SUSTAINED + THERMAL Mr = Mx2 + My2 + Mz2 = 0.00
TRANSFERRED TO 0.67Fr + 0.74Mr = 0.00
2 OUTLET = 0.00 ≤ 500 De PASSED
Fr = Fx2 + Fy2 + Fz2 =
EXHAUST
SUSTAINED
1455.63
(FOR REFERENCE)
Mr = Mx2 + My2 + Mz2 = 922.47
0.67Fr + 0.74Mr = 1657.90
3 SUSTAINED + THERMAL -489.50 -1112.50 801.00 678.00 407.00 475.00
= 1657.90 ≤ 500 De PASSED
Sum of 1,2,3, -311.5 -1557.5 489.5 949.3 610.5 312.0
Fc = Fx2 + Fy2 + Fz2 = 1662.06
Multiply the above forces by
-70.1 -350.4 110.1 702.5 451.8 230.9
0.225 and moments by 0.74 Mc = Mx2 + My2 + Mz2 = 1170.99
SM-23 Allowables -> 447.2 1118.0 894.4 2236.1 1118.0 1118.0
0.45Fc + 0.74Mc = 1614.46
Multiple ->
1 50 Dc 125 Dc 100 Dc 250 Dc 125 Dc 125 Dc = 1614.46 ≤ 250 Dc PASSED
0001.F2.DOC
FOSTER WHEELER
PIPING ENGINEERING
DSN:
TECHNICAL NOTES
APPENDIX 19
PIPE SUPPORT LOAD LIMITS FOR TRANSMITTAL TO CIVILS
SINGLE PIPES
The table below shows the limits for pipe forces, above which, loads MUST be transmitted to civils,
according to section 13.1.3
NB Pipe Diameter in mm Fx in kN Fy in kN Fz in kN
Upto 2" 60.3 0.9 1.8 0.9
3" 101.6 1.5 3.0 1.5
4" 114.3 1.7 3.4 1.7
6" 168.3 2.5 5.0 2.5
8" 219.1 3.2 6.4 3.2
10" 273.1 4.0 8.0 4.0
12" 323.9 4.8 9.5 4.8
14" and above ALL loads to be transmitted to civils.
MULTIPLE PIPES
For multiple pipes on one support/beam etc. use the following formula to find the limits for horizontal and
vertical loads
Fx = 1.5 x 9.81 x D D = Sum of Pipe Diameters. Not to exceed 300mm

Fy = 3 x 9.81 x D D = Sum of Pipe Diameters. Not to exceed 300mm
Where The sum of the pipe diameters exceeds 300mm use the figure 8829 Newtons
If The above limits are exceeded the loads must be transmitted to civils in all cases.
0001.F2.DOC
FOSTER WHEELER
PIPING ENGINEERING
DSN:
TECHNICAL NOTES
APPENDIX 20
TYPICAL SUPPORT MARK-UP
0001.F2.DOC

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FOSTER WHEELER

Client’s Name: ENOC Processing Company L.L.C. (EPCL)

Project Title: NAPHTHA HYDROTREATER REFORMER

16. EARTHQUAKE LOADS

1. EXTENT OF STRESS ANALYSIS - PIPING CONNECTED TO EQUIPMENT OTHER THAN

2. EXTENT OF STRESS ANALYSIS - PIPING CONNECTED TO ROTATING MACHINERY

3. EXTENT OF STRESS ANALYSIS - PIPING CONNECTED TO TANKS (NO FLEXIBLE

4. CALCULATION FRONT SHEET

5. FW ALLOWABLE LOADS EVALUATION TABLE FOR

6. STANDARD CALCULATION FRONT SHEET FOR DOCUMENTED HAND

7. MINIMUM DESIGN LOADS FOR VESSELS

8. MAXIMUM RECOMMENDED SPANS - CARBON STEEL

9. MAXIMUM RECOMMENDED SPANS - STAINLESS STEEL

10. EXPANSION COEFFICIENTS FOR STAINLESS STEEL

11. EXPANSION COEFFICIENTS FOR CARBON STEEL

12. CAESAR II CALCULATION SET-UP

13. SITE DESIGN CONDITIONS AND GOVERNING CODES

14. SPECIAL DIFFERENTIAL SETTLEMENT CONSIDERATIONS

15. STRESS NOMOGRAPH AND GUIDELINES

16. STRESS ISOMETRIC FORMAT

17. NOZZLE LOAD EVALUATION AT STEAM TURBINES

18. NOZZLE LOAD EVALUATION AT CENTRIFUGAL COMPRESSORS

19. PIPE SUPPORT LOAD LIMITS FOR TRANSMITTAL TO CIVILS

20. TYPICAL SUPPORT MARK-UP FOR 1-4 SUPPORT POINTS.

• The maximum allowable stress range of the piping material.

3.1 Codes and Standards

The following is a list of the relevant Regulations, codes and standards:

3.1.1 ASME B31.1 - Power Piping (Use where shown on flowsheet)

3.1.2 ASME B31.3-2002 - Chemical Plant and Petroleum Refinery Code

3.1.3 ASME VIII - Rules for Pressure Vessels

3.1.5 API 610, 9th Edition - Centrifugal Pumps

3.1.6 NEMA SM-23, API 617 - Steam Turbines.

3.1.7 API 661 - Air Fin Coolers.

3.1.8 WRC 107 - Welding Research Council Bulletin.

3.1.9 API 620, API 650 - Storage Tanks.

3.1.10 ENOC EDS-L-1. - ENOC Refinery Piping Standard

3.1.11 2731-59B50 - Pipe Support Standard.

3.1.12 BS 6399 - Wind loading/data

3.1.13 UBC-1 (1997) - Earthquake data.

3.2 Thermal Expansion

Temperature differential for flexibility calculations shall be maximum temperature

Maximum temperature shall be taken as the greater of:-

The minimum temperature differential to be used in flexibility analysis will be 500 C

3.3 Installed Temperatures

Temperature range for determining moments and forces on equipment nozzles

1) From the installation temperature to the maximum defined in 3.2

Site installation temperature(s) is listed in appendix 13.

rejected. For FW allowable loads, see Appendix 5.

3.4.14 In reviewing piping isometrics, or arrangement drawings, the Stress Engineer

4 STEAM OUT CONDITIONS

a) Line Hot, Equipment Cold, OR

5 SCHEDULE OF CRITICAL LINES

6.1.3 Approximate calculation methods may be applied in cases identified as category

6.1.4 Acceptable comprehensive methods of analysis include computer and analytical

PTFE ON PTFE = 0.1

6.1.7 When commencing a new calculation please make a copy of 2730-CA-Template,

6.1.11 For the calculation of reactions, including connections to equipment, the

6.1.12 Thermal movements between anchors shall be limited to 155mm. In exceptional

6.2 Piping at Pumps

6.3 Piping at centrifugal compressors and steam turbines

6.3.1 General Design

6.3.2 Design Conditions

Operating temperatures for each operating condition under consideration shall