PIPING STRESS ANALYSIS BY USE OF CAESAR II

INSTRUCTOR: ENG. MOHAMED I ABOU EL-ELLA

CHAPTER 1 – INTRODUCTION TO STRESS
ANALYSIS & DESIGN CODE

2
What is this course about

- The course provides the participants with training on performing piping stress
analysis using CAESAR II software.
- In addition, and to achieve the above properly, the course will cover the basic
background of the piping stress analysis field and the related codes and standards.

3
Introduction to Piping Stress Analysis

What is Piping Stress Analysis?

It is the understanding of the Piping System Behavior as well as the Governing

Codes Requirements in order to properly design a piping system

Piping System Behavior can be measured through the combined values of

numerous physical parameters, such as stresses, displacements, internal forces and
moments, and external reactions.

Governing Code Requirements contain the allowable values set for each of the
above mentioned parameters.

4
Introduction to Piping Stress Analysis
Why do we perform Piping Stress Analysis?

- To keep stresses in the piping system within code allowable limits.

- To keep nozzle loadings within allowable.
- To calculate design loads for sizing supports.
- To determine piping displacements.
- To solve for dynamic forces imposed on the system
- To help optimize piping design.

How to perform Piping Stress Analysis?

As mentioned before, to perform Piping Stress Analysis we have to understand the
Piping System Behavior to make sure that it follows the Governing Codes
Requirements

5
Types of Stresses
Radial (Hoop Stress)  Due to Pressure
 Wall Thickness Calculation

PD
S
2t
PD
t min 
2S
Tension/Compression  Due to Bending Tension/Compression  Due to Pressure
 (Tension)

  (Compression)  F=PA
M M PD
S i i = SIF
Z Z  (Tension) S 6
Z = Section Modulus 4t
D 2 t
Z
4
Categories of Stresses

Sustained Loads Cyclic Loads

(Primary Stresses) (Secondary Stresses)
• Pressure • Thermal Expansion
• Deadweight • Large bore header
• Wind movements
• Relief Valve Discharge • Seismic
• Steam/ water Hammer

7
Loads Cause Pipe Loads Cause
to Rupture Fatigue Failure
PIPING CODES
B31.1 Power Piping
B31.2 Fuel Gas Piping
B31.3 Chemical Plant and Petroleum Refinery Piping
B31.4 Liquid Petroleum Refinery Piping
B31.5 Refrigeration Piping
B31.8 Gas Transmission and Distribution Piping Systems
B31.9 Building Services Piping
B31.11 Slurry Transportation Piping Systems
Section III, NB/NC/ND-3600 Nuclear Power Piping

8
 Stress due to Sustained Loads
(primary stresses)

PDo 0.75iM A
 1.0 S h
4t n Z

Where
• P = internal pressure Do = Pipe outside diameter
• tn = nominal pipe wall thickness Z = section modulus
• i = stress intensification factor Sh = allowable stress (hot)
• MA = resultant moment loading due to sustained loads
9
Stress due to Occasional Loads
(primary stresses)

PDo 0.75iM A 0.75iM B

  1.2 S h
4t n Z Z

Where
• Sustained part = same
• MB = resultant moment loading due to occasional loads

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Stress due to Thermal Expansion
(secondary stresses)
iM C
S A
Z
iM C
OR S A  f ( S h  S L )
Z
Where
• i = stress intensification factor
• MC = range of resultant moments due to thermal expansion
11
SA = 1.25Sc + 0.25Sh
Allowable Stress Curves

• A106-Gr.C
• A335-P11
• A335-P22
• A335-P91
• A312-TP304

Materials
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Differences in Material Strength

Allowable Stress (psi)

Temp. Carbon Steel A335-P22 A335-P91
800˚F 10,800 15,000 18,700
1000˚F N/a 7,800 14,300
1065˚F N/a 5,320 12,120
13
P91 vs. P22 Wall Thickness

14
Thermal Expansion Table
B31.1 Appendix B

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Example

• 4” sch.80, A335-P22
Example Problem

Temp Actual Allowable

Stress Stress
(psi) (psi)
500°F 8,450 22,500
800°F 15,640 22,500
1000°F 20,750 20,700
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Guided Cantilever Method

17
Guided Cantilever Example

The thermal expansion for 50’ of A335-P22 @ 1000°F is:

 = 8.89in/100ft x 50ft = 4.45in

Calculate the required offset based on guided cantilever formula where:

OD = 4.5in
S = 20.7ksi (w/SIF = 1.0)

  (OD) 4.45  (4.5)

L 25 25
S 20.7
L 24.6 ft
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Determine The Size of an Expansion Loop using the
Guided Cantilever Method
Given: Material = A312 TP304
Operating Temperature, To = 450F
Layout: Outside Diameter, D = 10.75 in
Stress Allowable, SA = 27.5 ksi
Thermal Expansion Coef.,  = 4.41 in/100 ft

The layout shown can be idealized as two guided cantilevers each of length L and each absorbing
half of the thermal expansion between the anchors.

2 = H *  = 55 ft (4.41 in/100 ft) = 2.42 in,  = 1.21

L = 25[(*D)/SA]1/2 = 25[(1.21 in * 10.75 in)/27.5 ksi]1/2 = 17 ft
19
Example for larger diameter piping:
L = 25[(*D)/SA]1/2 = 25[(1.21 in * 18 in)/27.5 ksi]1/2 = 22 ft
Adequate Flexibility
(Ref: B31.1 Para. 119.7.1 (A.3))
Adequate flexibility may generally be assumed if a piping system satisfies the
following approximate criterion:
Where: D = nominal pipe size, in.
DY Y = thermal expansion of pipe, in.
2
0.03 L = developed length of pipe, ft.
(L  U) U = anchor distance, ft.

Example:
Given: Material = A 312 TP304
Operating temperature, T0 = 8000°F
=8.80 in/100 ft
Outside diameter, D = 10.75 in

U  20 2  (40  10) 2  30 2 36.9ft 10.75(4.13)

2
0.016  0.03 20
Y U / 100 46.9(8.80) / 100 4.13in (100  46.9)
L 20  40  30  10 100ft
Therefore layout is acceptable
 B31.1 TABLE 121.5
SUGGESTED PIPE SUPPORT SPACING
Suggested Maximum Span
Steam, Gas,
Nominal Water or Air
Pipe Size, Service Service
(NPS)
ft m ft m
1 7 2.1 9 2.7
2 10 3.0 13 4.0
3 12 3.7 15 4.6
4 14 4.3 17 5.2
6 17 5.2 21 6.4
8 19 5.8 24 7.3
12 23 7.0 30 9.1
16 27 8.2 35 10.7
20 30 9.1 39 11.9
24 32 9.8 42 12.8
NOTES:

(1) Suggested maximum spacing between pipe supports for

horizontal straight runs of standard and heavier pipe at
maximum operating temperature of 750 F (400 C).
(2) Does not apply where span calculations are made or where
there are concentrated loads between supports, such as
flanges, valves, specialties, etc.
(3) The spacing is based on a fixed beam support with a bending
stress not exceeding 2,300 psi (15.86 MPa) and insulated
pipe filled with water, or the equivalent weight of steel
pipe for steam, gas, or air service, and the pitch of the
line is such that a sag of 0.1 in. (2.5 mm) between supports
21
permissible.
Stress Analysis Work Process
Stress Analysis Work Process

Pipe Isometrics

Information
 P&ID-Pipe Sizes
Gathering  Design Conditions
 Class sheets
 Vendor Information
 Wind/ Seismic Criteria

Math Model
Preparation

Preliminary Stress
Analysis

Check Results NO
 Pipe Stress
 Nozzle Loads
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YES
 Send Loads To Pipe
Final Stress Analysis Support/Civil Groups
 Send Loads To Vendors
Math Model
• Pipe Properties
• geometry
• diameter, schedule
• material
• insulation, fluid
• Stress Intensifications
• Boundary Conditions
• Pipe supports
• Equipment anchors
• Loads
• pressure
• thermal expansion
• wind/ seismic

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Analyzed vs. Non-analyzed
• Based on Temperature
CS & Low Alloy > 400F (2.7 in/100ft)
SS > 300F (2.6 in/100ft)
• Based on Importance
Sensitive Equipment: (Feedwater, Ext. Steam, Fuel Gas)
Non-standard components: (Relief valves, Expansion joints)
Headers or Equipment with large movements
• Based on Unique Criteria
Cross-country, Yard Piping (solar radiation)
Fiberglass, Nozzles connected to Large Tanks
Underground greater than 150°F
24
CHAPTER 2 – SYSTEM MODELING

25
Introduction to CAESAR II system modeling
Element Types

- Delta Dimensions
- Pipe Element & Pipe Section Parameters
- Elbow Element
- Miter Element
- Rigid Element
- Expansion Joint Element

Restraints & Displacements

- Anchors
- Single and Double Acting Restraints
- Friction, Gap & Stiffness
- Connecting Nodes
- Translational & Rotational Restraints
- Modeling of Restraints on Bends
- Bi-Linear Supports
- Rigid Hangers
- Spring Hangers & Supports
- Snubbers
26
- Applied Displacements (consideration in the load cases)
- Restraints with Displacements & Stiffness
- Skewed Restraints
Piping Component and Rigid Elements
Element Dimensions & Node Coordinates

For each node, the differential dimension with respect to the previous node is
defined as delta dimension ( X, Y, Z).

Alternatively the length of the element and the direction cosines are entered.

For nodes which start a new disconnected line inside the same model, the global
coordinates are
entered for the first node.

Pipe Elements

The pipe element section properties are entered in the spread sheet as pipe outside
diameter or
nominal diameter , wall thickness, corrosion allowance, mill tolerance and insulation
thickness.
27
All pipe section data are carried forward for the subsequent elements until they are
changed.
Rigid Elements

The weight and length of the element are entered for rigid elements. For standard
flanges and valves which are available in the database, the weight and length can be
input directly by the program.

The stiffness of the rigid element is proportional to the rigidity of the pipe with the
entered diameter and thickness. Therefore, the diameter and thickness for the rigid
element should be considered in the definition of the element.

For the non-zero weight rigid elements, the program adds the weight of fluid as equals
to the fluid weight of an equal length of pipe and adds the insulation weight as 1.75 of
that of equal length of pipe.
For zero length rigid element, it is assumed that they are used for modeling purpose and
no fluid or insulation is added.

28
Modeling of Elbow

29
Modeling of Flanged Elbow

30
Modeling of Elbow with Trunnion

31
Modeling of Reducers

32
Restraint and Displacement
MODELING OF RESTRAINTS

The following are the types of restraints available in CAESAR II input spread sheet:

Anchor: ANC
Translation: X, Y, Z, +X, -X, +Y, -Y,+Z, -Z
Rotational: RX, RY, RZ, +RX, -RX, +RY, -RY,+RZ, -RZ
Guide: GUIDE
Limit Stop: LIM, +LIM, -LIM
Spring Support: XSPR, YSPR, ZSPR
Snubber: XSNB, YSNB, ZSNB, + XSNB, +YSNB, +ZSNB, -XSNB, -YSNB, -ZSNB
Translation Bilinear: X2, Y2, Z2
Rotational Bilinear: RX2, RY2, RZ2
Large Rotation Rod: XROD, YROD, ZROD

For each restraint we define the restraint node and an optional connecting node
(Cnode).
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Anchors

They represent complete fixation of the point of support against translation &
rotation such as welded or bolted support.

When a stiffness is provided it is applied to all degrees of freedom at the anchor

point.

Anchors can also be modeled as 6 restraints provided with stiffness to model the
different flexibility of the anchor in the different directions.

To provide flexibility and displacement at the anchor, connecting node (Cnode) is

defined and the displacement is applied at the Cnode.

34
Translational Restraints

They can be single acting (directional), i.e. acting in +ve or –ve direction or
double acting, i.e. acting in both +ve and –ve directions.

They are always in the direction of the global axes. The restraints +X
represents the case when the support reaction acts in the +ve X-direction.

For each restraint, we can define three additional input data : coefficient of
friction, gap and stiffness.

The gap is always positive and it is taken to apply in both directions for the
double acting and to apply in single direction for the single acting.

The restraint symbol can be succeeded with the cosine angles for restraints
acting in inclined directions.

35
Rotational Restraints

They can be single acting or double acting, similar to the translational

restraints.

Guide Restraint

The GUIDE restraints act as a restraint in the horizontal direction

perpendicular to the pipe axis for skewed lines. For vertical lines it acts in
both horizontal directions.

36
Limit Stop

Limit stop is a restraint acting in the axial direction of the pipe. The restraint can be
double acting or single acting in the +ve or –ve directions. A gap can be applied as for
the translational restraint.

Spring Support

The restraints presents a spring with an initial force F, spring stiffness and a maximum
travel (deflection) x, after which the spring becomes rigid support. This is used for an
existing spring support.
For the case of the selection of a new spring support, the spring hanger data sheet is
used.

37
Snubber Restraint

A restraint acting only during the dynamic load cases only and free during
static load cases.

Bilinear Translational and Rotational Restraints:

They represent flexible supports with variable stiffness. The stiffness can take
2 values K1 and K2. Fy is the yield load which corresponds with the force at
which the stiffness changes from K1 to K2.

C-Nodes

C-Nodes can be used to connect geometry such as connecting piping

and structure models or 2 input piping files.
They are also can be used to connect several nodes to a virtual node
where displacement or load is applied. To switch between these 2
modes of use the Configuration setup file has to be changed .
38
Applied Displacement

Applied displacement can be defined for a node as 9 vectors V1, V2, V3, … and each
vector has 6 components X, Y, Z, RX, RY, RZ, corresponding to the 3 translational and
3 rotational degrees of freedom at the node.

It is important to note that if a component is not defined (left blank) that means this
degree of freedom is free and not restrained. Therefore to apply zero displacement
at a node a zero has to be entered.

It is also important to note that if a displacement vector component is defined for a

node, then this component is zero for the load cases where the applied
displacement is not included.
This is understood as a consequence of the fact that the applied displacement at a
node represents thermal displacement at this node.

39
Model of Anchors

40
41
MODEL NONLINEARITIES

CAESAR II handles certain types of nonlinearities in the boundary conditions (model restraints).
These types are:

Friction in the sliding supports

Gaps in the supports
Single acting supports
Bilinear stiffness support

The solution of the system equations for nonlinear system is an iterative solution. It is important to
bear in mind that in many situations the iterative solution cannot reach a convergent solution and
for nonlinear problems, there might be even more than 1 solution where the software will give
only the first convergent solution.

The friction force direction will not only depend on the present system temperature but also on the
history of the displacement and the temperature variation. This explains the fact that for long lines
anchor force will be different for startup and shutdown scenarios for the same system operating
temperature.

42
Operating Conditions

The operating conditions of temperature and pressure are defined for each element. The
input values for the an element are carried forward for the subsequent elements until
they are changed. There can be up to 9 operating conditions.

Inside the temperature field the total thermal expansion (mm/mm) can be entered. The
program takes the value entered as expansion if it is less than Alpha Tolerance as defined
in the setup file.

43
44
CAESAR II input window

45
Input layout

46
First element Input

47
Element summary

48
Elbow screen

49
Rigid element screen

50
Valves data base

51
Valves data base

52
Reducer screen

53
Sif or Tee connections

54
Sif or Tee connections

55
Sif or Tee connections

56
Sif or Tee connections

57
Restraints

58
Restraints

59
Restraint with displacement

60
Nozzles

61
Concentrated Forces

62
Wind input

63
Uniform loads (Seismic)

64
Uniform loads (Seismic)

65
Allowable

66
Allowable

67
Allowable

68
Materials

69
Materials properties

70
Listing window for pipe element summary

71
Edit screen

72
Model menu

73
Execution parameter

74
Include piping files

75
Include piping files

76
Configuration setup

77
Configuration setup

78
Configuration setup

79
Configuration setup

80
Configuration setup

81
Configuration setup

82
CHAPTER 3 – STAIC ANALYSIS OUTPUT
AND SEQUENCE OF CHECK.

83
Load Cases Types and Definitions
Static analysis starts by the definition of the load cases to be considered in the analysis.
The load cases are built by combining the different applied loads and design conditions
in a set of load cases. The loads considered for combination are:

• W : weight of piping, insulation and fluid

• WW weight of the system water filled
• WNC: weight of the system without contents
• Temperature: operating temp T1, T2, … ( max T9)
• Pressure: design pressure P1, P2, … (max P9) plus hydrotest pressure
• Forces: applied concentrated force vectors F1, F2, … ( max F9)
• Displacement: imposed displacements at restrained nodes D1, D2, … ( max D9)
• Uniform loads: applied loads distributed along the pipe U1, U2, U3 (N/m or g’s)
• Wind: applied wind loads WIN1, WIN2, WIN3, WIN4
• CS: Cold spring defined as material with the cold spring as the length of the element 84
• H: spring support forces and spring support stiffness
Load cases are given load case number L1, L2, … and classified with the type depending
on the code stress definition. The main code stress classifications of the load cases types
are:

• OPE: operating load case

• SUS: sustained load case
• EXP: expansion load case
• HYD: hydrotest load case
• OCC: occasional load case
• FAT: fatigue load case with the number of cycles defined

85
Load Combinations
The simple set of load cases, which can be obtained as a recommended for the main
code stress equations, are as follows:

• W+P1+T1 as operating load case L1

• W+P1 as installed or sustained load case L2
• L1-L2 as combined expansion stress range load case L3 For the case of maximum
operating temperature T1 and minimum operating temperature T2 (below the installed
temp.), then:
• W+P1+T1 as operating load case L1
• W+P1+T2 as operating load case L2
• W+P1 as installed or sustained load case L3
• L1-L3 as combined expansion stress range load case L4
• L2-L3 as combined expansion stress range load case L5
• L4-L5 as combined expansion stress range load case L6 86
For the case of a spring support, the following load cases as example:

• W : spring support design load case

• W+P1+T1 : spring support design load case
• W+P1+T1+H as operating load case 3
• W+P1+H as installed or sustained load case 4
• L3-L4 as combined expansion stress range load case 5

87
For the occasional load cases, we consider the following:

• W+P1+T1 as operating load case ----- LX1

• W+P1+T1+ WIN1 as operating load case & wind ----- LX2
• W+P1 as installed or sustained load case ----- LX3
• Wind only load case: LX2 – LX1 ----- LX4
• Code occasional stress load case LX3 + LX4 (scalar combination)

88
The method of combination is algebraic as default. The required method of
combination is defined for each combined load case.

Algebraic: the default combination method for which the displacement and
the force vectors are added algebraically and then the stresses are
computed from the resultant.

Scalar: algebraic combination of displacement and forces. The stresses are

added as scalar (absolute value). Used for code occasional stress

Absolute: the absolute values of displacement, forces and stresses are

added.

89
LOAD CASES INPUT

90
91
92
93
System error check

94
95
The static analysis results report the following:

• Nodal Displacement: the nodal displacement corresponding to the 6

nodal DOF.

• Restraint Report: reaction forces acting from the piping at the

Supports.

• Element Forces: elemental forces in the global and local

Coordinates.

• Stress: Stresses and SIF for each element at the nodes.

• Code Compliance Report: check of the stresses according to the

design code.

96
RESULTS REVIEW

97
98
99
100
101
102
Static Analysis Example

103
104
Modified Line Layout & Support

105
106
CHAPTER 4 – SPRING SUPPORTS
AND ADVANCED TOPICS.

107
SPRING SUPPORTS
Spring supports are used to support the weight of the piping system and at the
same time allow movement of pipe such as that due to thermal expansion.

By proper design of the spring support, pipe stresses and forces transmitted to
connected equipment are kept within allowable limits. Spring supports are used

• Large vertical displacements and/or connection to a load sensitive

• Near connections to vessels subjected to large differential settlement

• Even with limited thermal displacements, we may consider using spring supports
in rigid vertical runs to compensate for thermal displacement
equipment. And/or small errors in the fabrication and installation.

We should consider using rigid pipe hangers or supports at the points where the
pipe displacement due to thermal expansion is limited and the piping system is
flexible such that placing rigid support will not introduce large forces or stresses in
the system. 108
where:
There are 2 types of spring supports:

• Variable spring support: the most common type is the variable spring
type. For the variable type, the spring applies a variable reaction
force on the pipe due to pipe displacement.

• Constant effort support: the constant effort support uses a

mechanism to balance the spring displacement such that the
reaction force of the support is approximately constant over certain
displacement range. Constant effort spring support is limited to the
cases where the pipe displacement is large such that the use of
variable spring support fails to satisfy the allowable limits on pipe
stresses or equipment forces

109
110
111
Variable spring supports can be:

• Spring hangers
• Spring can supports.

The design Codes ASME B31.1 & B31.3 provide requirements for piping supports.

The reference standards for the material, selection, fabrication and

installation are: MSS SP-58, SP-69 & SP-89.

112
The following lists the basic requirements of ASME B31.1:

• Spring supports are designed to carry all weight loads including

those due to the hanger parts.

• The maximum load variation due to thermal movement is limited to

25% for variable spring support and 6% for constant effort spring support.

• They should be provided with means to limit misalignment, buckling

and eccentric loading.

• They should be provided with means to indicate at all times the

spring compression with respect to the hot and cold positions.

• Counter weights and hydraulic types can be used for the constant
support. They have to be designed so as to include safety devices
support.
and stops.

113
Many manufacturers provide wide variety of pre-engineered pipe
supports hardware including spring supports. These include:

• Lisega
• Carpenter & Paterson
• Pipe Supports Ltd.
• Piping Technology
• Inoflex

114
Generally there are different spring coil sizes with catalogue number to
indicate the coil size and the support form and details. For each coil size
there are:

• Short Length
• Standard Length
• Long (can be 2 and 3 times the standard)

The selection between the different types will be governed by the amount of
travel, the amount of acceptable load variation and the available space.
For the short spring, the spring rate is high and the amount of travel is
limited. For the longer types, the spring rate is lower and the allowable
travel is larger.

115
C II APPLICATION TO SPRING SUPPORT Refer to the example in
the next slide:

• Nominal Diameter: 6" Schedule 40

• Operating Temperature: 120 C
• Installed Temperature: 10 C
• Pressure: 10 Bar, Gas
• Material: A106 B
• Insulation thickness: 25 mm

116
117
Hanger Design Control Data

118
119
Special Execution Parameters

120
Hanger Load Cases

121
122
Spring Support additional options

123
EXPANSION JOINT

Expansion Joints are used in piping systems to reduce expansion stresses, reduce piping
reactions on connecting equipment and to isolate mechanical vibration. Basically expansion joints
are used when it is necessary to provide a large amount of flexibility in a small space.

The main factor which influences the decision to use expansion joints is limited space and large
diameter low pressure piping.

There are two general styles of expansion joints; Bellow type, designed in accordance with
Appendix X of the ASME B31.3 Code and slip-joint type designed according to Article 304.7.4 of
ASME B31.3 Code. Slip type joint can absorb displacement in the axial and torsional direction,
while bellow type expansion joint can absorb displacement in axial, lateral and angular direction.
Bellows type expansion joint is the more commonly used type of expansion joints and is used in
many different types of arrangements as single, universal, hinged or gimbal joint.

Expansion joints are constructed out of sheet metal (mostly stainless steel, but can be any other
metallic material) through rolling in cylindrical shape with corrugations (also called convolutions)
and welding. The sheet is made of 1 or several layers (plies). The expansion joints element can
vary in terms of the material, the number of convolutions, the number of plies, the pressure
capacity, the stiffness and the allowable movement. 124
For most part, these details are taken care of by the expansion joint manufacturer. A typical
expansion joint piping design proceeds as follows:

- The decision is made to use an expansion joint after evaluating alternatives

- Estimation of the required amount of displacement in the different directions is made. This is
usually done by assuming that the expansion joint has zero stiffness and the free movement of
the piping is calculated.

- Based on the design temperature and pressure a standard expansion joint is selected from a
manufacturer catalogue.

- The properties of the selected expansion joint are inserted in the piping model and the
response of the system as stresses, forces and displacements is checked.

- For each bellows there is a limit to the cumulative axial, lateral and bending displacement that
can be absorbed. This limit is also related to the allowable number of stress cycles according to

the fatigue life of the element. The main factor in the design of the bellow element is the fatigue
life under the applied number of stress cycles.
- In case the applied cumulative displacement is above the bellows limit, increasing the number
of convolutions can be the solution.
125
BELLOW ELEMENT DISPLACEMNET

126
END PRESSURE FORCE

End pressure force Fp = Pressure x Effective area = P. /4 . De 2

127
128
EXPANSION JOINT STIFFNESS
The stiffness in the axial, transversal and torsional directions are specified. For bellow element
the bending stiffness is calculated from the transversal stiffness. If not known the torsional
stiffness is left blank and it is taken as rigid (large value 0.1 E +05).

Bending stiffnesses from EJMA (and from most expansion joint manufacturers) that are to be
used in a finite length expansion joint model should be multiplied by (4) before being used in any
piping program. Bending stiffnesses from EJMA (and from most expansion joint manufacturers)
that are to be used in a ZERO length expansion joint model should be used without modification.

For completely flexible element stiffness is entered as 1 and for completely rigid element stiffness
is entered as 1 E+12

The effective ID is defined for calculation of the pressure thrust force.

Expansion joint can be defined with zero length to simulate hinged connections.

Four stiffnesses are required to define the stiffness of the expansion joint:

Axial Stiffness
Transverse (lateral) Stiffness 129
Bending Stiffness
Torsional Stiffness
The transverse and the bending stiffnesses are directly related when a finite length joint is
defined. In this case the bending stiffness should be left blank and the transverse stiffness
entered.

When the expansion joint has a zero length, none of the expansion joint stiffnesses are related. In
this case the user must be sure that a value is entered into all four of the stiffness fields.

The expansion joint axial force F is given by:

F = ka x = Ka X

Where:

Ka = axial stiffness of the bellow element

X = axial displacement of the bellow element

ka = axial stiffness per convolution

x = axial displacement per convolution

N = number of convolutions
130
ka = N Ka

x =X/N
The lateral stiffness can be estimated approximately from the axial stiffness if not
given explicitly by the supplier:

Kt = 1.5 Ka (D / L )2

The approximate relationship between the bending stiffness (as used in the piping
analysis software) and the axial stiffness:

Kb = 0.5 ( / 180 ) Ka D2 (finite length)

Kb = 0.125 ( / 180 ) Ka D2 (zero length)

D: effective diameter of the bellow element

L: flexible length of the bellow element

131
MODELING OF EXPANSION JOINT
Expansion joint modeler can be used to model the complete joint with all elements
(including the rigids) from different suppliers catalogues. The expansion joint element is
specified by specifying the delta dimension and the bellow element stiffnesses. The tie-rods
are modeled by use of rigid or pipe elements.

132
Expansion Joint Selection Example:
Line: 20” Std wall thickness

Material: Stainless Steel

Design Temp. = 220 C, Max Operating Temp. 200 C

Design Pressure = 7 barg
Insulation 60 mm Calcium Silicate
Layout as shown

Service life 20 years,

Thermal stress cycles 1 cycle per week.
Specify expansion joint details

133
Solution:
Input Data

134
135
Expansion stress for the present configuration: 136
Expansion joint is to be inserted in the run from node 130 to node 160. This will
eliminate the need for pressure force anchors since the expansion joint will be tied
rodded and will take only lateral displacement.

137
Sizing of the Expansion Joint:

Release the anchor at node 160 and find the displacement at this node for the total
thermal expansion range.

The required capacity of the Expansion Joint is 60 mm.

138
The number of cycles = 20 year X 52 week / year X 1 cycle / week = 1040 cycle

Select the expansion joint which correspond to the required displ and number of cycles from the
standard catalogue.

For Flextronics catalogue, the maximum lateral displ for a single bellow element is 29.1 mm.

Select a universal tied expansion joint. The joint is made up of 2 bellow elements 4 corrugations
each. From the catalogue page 35, diameter DN 500, pressure 10.5 barg, and 4 corrugations:

Length Le = 241 mm,

Axial Spring rate = 136 kg/mm = 1333 N/mm

Lateral spring rate = 7602 Kg/mm = 74500 N/mm
Effective area = 2329 cm2, then effective diam = 544 mm

A spool of 1000 mm is used between the 2 elements.

The total length of the exp joint = 200 + 241 + 1000 + 241 + 200 = 1882 mm

The exp jt is inserted between nodes 140 to 145 as:

140 to 141 end pipe spool 200 mm

141 to 142 exp jt bellow element: stiffness and equiv. diam
142 to 143 long pipe spool = 1000 mm
143 to 144 exp jt bellow element: stiffness & equiv diam 139
144 to 145 end pipe spool 200 mm

Restraint between 141 and 144 to represent the tie rods as: Z, RX, RY
140
141
142
C II has a built in catalogue of Flextronics and other suppliers. The selected exp jt including
the type, number of corrugations, … is modeled.

It is important to note that the stiffness of the bellow element in the lateral direction is
much higher
than the stiffness of the whole joint. 143
The following are the screen of CII modeled Expansion Joint :

144
145
Equipment Code Compliance
Equipment Code Compliance

Piping Nozzle Evaluation

The three possible types analyses which may be done on

nozzles are:

- Evaluation of equipment loads

- Calculation of vessel stresses (WRC 107)
- Calculation of piping/vessel connection flexibilities (WRC 297)
Equipment Code Compliance

1 Evaluation of equipment loads

1.1 NEMA SM23 Standard for Steam Turbines

- Individual nozzle allowable

3F+M<500De

Where:
F= resultant force on the individual nozzle
M=resultant moment on the individual nozzle
De=nominal pipe size of the connection
Equipment Code Compliance

- Cumulative equipment allowables

Fx<= 50Dc
Fy<= 125Dc
Fz<= 100Dc
Mx<= 250Dc
My<= 125Dc
Mz<= 125Dc
Fc+Mc/2<=125Dc

Dc = diameter of an opening whose area equal to the sum of all areas

of all nozzles.
Equipment Code Compliance

1.2 API 610 Standard for Centrifugal Pumps

1.2.1 Horizontal Pumps

• Allowable nozzle loads are based on:

• Code Limits for misalignment between the pump and driver.
• Code Limits for pressure casing distortion
Equipment Code Compliance

• Clause F.1.1 states that the individual component nozzle loads

must fall below the allowables listed in the Nozzle Loadings
table 4.
Equipment Code Compliance
 Equipment Code Compliance

a) The individual component forces and moments acting on each

pump nozzle flange shall not exceed the range specified in Table 4.

If clause F.1.1 is NOT satisfied, piping configurations could be

acceptable if the conditions specified below are satisfied.

b) The resultant applied force (FRSA, FRDA) and the resultant applied
moment (MRSA, MRDA) acting on each pump nozzle flange shall
satisfy the equations below:
[FRSA / (1,5 × FRST4)] + [MRSA / (1,5 × MRST4)] ≤ 2
[FRDA / (1,5 × FRDT4)] + [MRDA / (1,5 × MRDT4)] ≤ 2
Equipment Code Compliance

c) The applied component forces and moments acting on each

pump nozzle flange shall be translated to the centre of the
pump. The magnitude of the resultant applied force (FRCA),
the resultant applied moment (MRCA), and the applied
moment shall be limited by the following equations:

FRCA < 1,5 (FRST4 + FRDT4)

| MYCA | < 2,0 (MYST4 + MYDT4)
MRCA < 1,5 (MRST4 + MRDT4)
Equipment Code Compliance
Equipment Code Compliance

1.2.2 In line Vertical Pumps

• The forces and moments can be larger than 2 times the table 4
values provided that the principal stress in the nozzle does not
exceed 41 MPa. The principle stress is calculated based on a
pipe with same diameter as the nozzle and schedule 40.
P =  / 2 + (2 / 4 + 2 ) 0.5 < 41 MPa
=F/A+M/z& =F/A+T/2z
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance

• The input for C II include the data of the suction and discharge
nozzles:
• Nozzle node number.
• Nozzle orientation ( top, side or end).
• Nozzle diameter.
• Nozzle distance from the base point.
• Nozzle loads, which can be obtained from the output file if
nozzle.
• node number is specified.
Equipment Code Compliance

• Discharge Lines
Equipment Code Compliance

• EXAMPLE OF PUMP SUCTION & DISCHARGE SYSTEM

• Suction Lines
Equipment Code Compliance

• Modified Suction Line

Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance

2 Calculation of vessel stresses (WRC 107)

a) d/D < 0.33

b) Dm/T>50, where Dm = D – T, mean vessel diameter
c) Calculates vessel stress only.
d) Used for cylindrical and spherical vessels
Equipment Code Compliance
Equipment Code Compliance
Equipment Code Compliance
 Equipment Code Compliance

3 Calculation of piping/vessel connection flexibilities (WRC

297)

a) d/D <= 0.5

b) D/T<=2500
c) d/t <=100
d) Calculates vessel stress and nozzle stress
e) Used for cylindrical nozzle on cylindrical vessel
Equipment Code Compliance
CHAPTER 5 – DESIGN CONSIDERATION AND
BASICS OF CAESAR II DYNAMIC ANALYSIS

177
Feedwater Suction Consideration

178
Feedwater Discharge Design Considerations

• Pump Nozzle allowable

• High pressure, thick wall pipe
• Recirculation lines
• Affect pump loads due to close proximity
• often need more flexibility
• need to be restrained for transients

179
Feedwater Discharge Design Considerations

180
Blowdown System Design Considerations

• Blowdown Tank Nozzle allowables generally low

• Pipe can be high pressure, thick wall
• Thermal movements at vendor interface can be
significant
• Design vs. service temp

181
Blowdown

182
Small Bore Critical Design Considerations

• Thermal movements at header tap significant

• Usually A335-P22 with much lower allowable
• Deadweight significant
• Large, heavy control valves
• 2” to 3” of insulation
• Requires many supports
• Slope requires detailed review

183
Condensate System Design Considerations

• Pump Nozzle allowables generally low

• Low temperature but still requires flexibility
• Long, straight segments difficult to support/restrain
• Usually have a pump idle/ standby (similar to Feedwater)
• Subject to transients and water hammers when starting
pump

184
Condensate Discharge

185
Fiberglass Piping Design Considerations

• Cost effective for transferring non-standard fluids

• Pressure rating and manufacturing process significantly
affect material properties
• Thermal expansion similar to stainless steel
• Must strictly adhere to vendor design and supporting
instructions
• Failure mode is catastrophic
• Compression much better than tension & bending

186
 Underground Piping Design Considerations

• Underground services (typically fuel gas) greater than

150°F require stress review
• Consider routing above ground
• Complicated analysis
• Variables that affect analysis
• temperature, pipe size, pipe schedule, straight lengths
• soil properties, depth buried, trench width

187
Piping Connected to Large Tanks Design Considerations

• Affects from settlement (long & short term)

• Affects from Tank bulging and thermal expansion
• Seismic requirements
• Expansion joints vs. piping offsets

188
Large Tanks

189
What is a water hammer or steam hammer

– Water Hammer (or a Hydraulic shock) is a momentary

increase in pressure inside the pipe caused by sudden change
of direction of velocity of the liquid or steam in the pipe.
– Water hammer is a short time event (few seconds) can be
catastrophic because the increase in pressure can generate
large forces that can be severe enough to damage pipe
supports, rupture a pipe or damage equipment

190
 These photos are an example of the powerful forces generated by steam hammer. In this
case, the steam hammer occurred in a power plant, on a high temperature steam header, and
caused many pipe failures.

 As a result the pipe moved off it’s supports and was displaced by as much as 1 m. The power
plant was out of service for 3 months in order to repair the damages.
191
How is water Hammer caused

PA PA P2A P1A

F=0 F=P1A-P2A

(A) Valve Open (C) Un-Balanced Forces are

(B) Valve Suddenly Closed
V = 10 m/Sec Generated in the pipe axial
V = 0 m/Sec
Direction

Water hammer most commonly occur when a valve is closed quickly and suddenly stops the flow of
liquid in a pipeline. This causes the velocity to decrease (ex: V1=10  V2=0)

A change in velocity V is causing the pressure to increase ΔP = ρ.C.ΔV

ΔP = Pressure increase, ΔV = Velocity increase, C = Sound velocity, ρ = Fluid density
This sudden rise in pressure generates a shock wave which travels back and forth through the piping
system equal to the speed of sound in the liquid.

These pressure waves generate impact forces on opposing elbows that act in the axial direction of pipe
that cause the pipe to sway with large pipe deflections in a violent manner that damage the pipe
supports and equipment F= ΔP. A . Ls/C.t
Valve Closure
A Pipe flow Area, Ls Pipe length, t Valve closure time flow

192
time
t
How is water hammer caused

Bumper
Support

-------- Pipe movement

Valve due to water hammer Valve
suddenly suddenly
_____ Pipe Center line
closed closed
193
 Relief valve Closed Discharge
pipe
Safety/relief valve fast opening
causes pressure surge in the
pipe
Pressure increase cause Water
hammer in both the discharge
and header pipes

194
Sources of water hammer

• Valves and equipment not operating as designed

• Fast closing of control valves
• Not draining the system properly, water is accumulating at a
low point in steam piping during plant startup
• Operators not following proper procedures
• Rapid pump startup or rapid pump shutdown
• Rapid safety/relief valve opening
• Movements of air packets in the pipe (venting air from pipe)

195
Guidelines for Analyzed systems

Locate rigid vertical and lateral

supports (double acting) near
valve stations especially near
control valves Preferably and if
feasible the valve stations shall
be on rigid supports and not
on springs

196
Guidelines for Analyzed systems

Minimize the use of very long

rods. Rods are only act as
tension members and offer no
resistance for upward loads.
They offer little or no
resistance to vibration or
transients.

197
Guidelines for Analyzed systems

On long risers place a double acting

support (rather than a rod hanger)
next to the top elbow to restraint
for vertical upward loads due to
dynamic transients OR locate an
axial restraint (good location is top
1/3 of riser)

198
Guidelines for Analyzed systems

On long risers locate guides to

keep the riser stable (at two
different locations, top 1/3 and
bottom 1/3 if feasible)

199
Guidelines for Analyzed systems

If feasible, locate guides close

to change in direction

200
Guidelines for Analyzed systems

Consider support
enhancements such as
bumpers for pipe that is
very flexible where thermal
and dynamic movements
can be very significant (i.e.
at loops).

201
Guidelines for Analyzed systems

Ensure that we do have some

double acting vertical
restraints to provide some
defense against the pipe
jumping off from its supports.

202
Guidelines for Analyzed systems

When struts are used for

combined vertical and lateral
support it is more effective to
keep the angle between the
two struts at or close to 90
deg. This will keep the lateral
movement minimum and make
the system more effective for
vibrations and transients.

203
Guidelines for Analyzed systems

Consider the use of Snubber or

bumper supports in the case
when pipe flexibility
requirements does not permit
putting Rigid supports and
these Snubbers are preferred
to be used in high temperature
lines such as MS, CRH and HRH
pipes.

204
 Guidelines for Analyzed systems

• Ensure that in the case of

the pipe support drawing
shown the pipe will not fall
off it’s support.
• Consider axial restraint with
gaps More than thermal
movement of the pipe.
• Provide large plate

205
Guidelines for Non analyzed systems

For non analyzed systems that may experience transients such as

• Condensate system,
• Spray water system,
• Fuel oil,
• Low temperature extraction, etc.

Use the following rules:

206
Guidelines for Non analyzed systems

Review the pipe support scheme and ensure that there are:

• Adequate lateral restraints on long segments and vertical

risers, especially at each change of direction

• Locate guides close to changes in direction on long horizontal

spans

• Use the minimum load criteria for the first lateral restraint and
ensure that there is adequate stiffness such as adding a brace
etc. if this does not add to the cost significantly

• On long risers place a double acting support (rather than a rod

hanger) next to the top elbow to restraint for vertical upward
loads due to dynamic transients

207
Guidelines for Non analyzed systems

Review the pipe support scheme and ensure that there are:

• For the remaining supports on long horizontal segments place a

lateral restraint and double acting vertical supports (U-bolts,
frame etc.) every third or fourth dead weight support to restraint
from uplift. These supports do not see significant loads during
transients and should be designed with the wind/seismic
requirements.

• For axial restraints use the minimum load criteria and adequate
stiffness such as brace on a post etc.

• For piping that experience large thermal movements ensure that

there is protection against the piping falling off the support.
Consider the use of large saddles or bumpers supports if they are
cheap to install and do not add to the cost.
208
Summary

• Manage the risk of catastrophic failure

• Add extra line of defense to lessen the damage. Example:
• Add restraints at strategically chosen locations
• Minimize fast closing valves and tripping of equipment
through effective control logic.
• Operating/maintenance procedures (i.e. dirty steam
traps, drains not operating properly)
Use Engineering judgment to balance the added cost

209