Piping Stress Analysis Engineering

Total Pages-13
IRUP
ENGINEERING DESIGN BASIS

RESIDUE UPGRADATION AND MS/HSD
QUALITY IMPROVEMENT PROJECT
INDIAN OIL CORPORATION LIMITED,
GUJARAT REFINERY
JOB NO
: __6235___
DOCUMENT NO.
: __H-159__
PIPING STRESS ANALYSIS
10/06/2006
For BID DOCUMENT
REV.
DATE
DESCRIPTION
MADE BY
TOYO ENGINEERING INDIA LIMITED

MUMBAI
INDIA
CHCKD
APPRVD
PM
TOYO ENGINEERING INDIA

LTD.
ISSUED : DATE: Aug.18/06
DOCUMENT NO. H-156
JOB NO. : 6235
(RESIDUE UPGRADATION AND MS/HSD

QUALITY IMPROVEMENT PROJECT)
SHEET 2 OF13
Table of contents
Section
Page

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DOCUMENT NO. H-156
1.0
SCOPE
This specification gives directives for the design, selection criteria, methods for pipe stress design
for aboveground piping. The intent of this specification is for RESIDUE UPGRADATION
PROJECT of IOCL, VADODARA, GUJARAT, India, not to supersede the applicable Codes, but to
supplement them with certain conditions not fully covered therein.
2.0
REGULATIONS
The following codes, standards and specifications shall form a part of this specification to the extent
specified therein:
2.1
CODES
American Society of Mechanical Engineers (ASME)
B31.3 ,2004 Process piping.
B31.1 Power piping.
IBR Latest edition
2.2
STANDARDS
American Petroleum Institute (API)
API 610 (2004)
API 611 (1997)
API 612 (2003)
`
API 617 (2002)
API 618 (1995)
API 661 (2002)
API 560 (2001)
API 686 (1994)
API 520 (2000)
Centrifugal pumps for general refinery services

General purpose steam turbines for refinery services
General-purpose steam turbines for petroleum, chemical
and gas industry services
Centrifugal compressors for general refinery services.
Reciprocating compressors for general refinery services
Air-cooled heat exchangers for general refinery services
Fired heaters for general refinery services
Recommended Practices for Machinery Installation and Installation Design
Recommended Practices for Safety Valve installation
National Electric Manufacturers Association (NEMA)

SM-23 Steam turbines for mechanical drive service
2.3
MANUFACTURER'S STANDARDIZATION SOCIETY (MSS)

MSS SP-58
MSS SP-69
MSS SP-89
Pipe hangers and supports.-Materials, Design and Manufacture

Pipe hangers and supports.-Selection and Application
Pipe hangers and supports.-Fabrication and Installation Practices

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DOCUMENT NO. H-156
2.4
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

Manual of steel construction.
2.5
REFERENCE SPECIFICATIONS
H-100
A-6235-049-001
H-6235-11-T-130-001
3.0
Standard Engineering Spec. for Plant Layout

Project Design Basis - Piping
Piping Material Specification
DESIGN CONSIDERATION
The piping flexibility analysis shall be performed by using CAESAR II software Version 5.0, that
contains the codes as mentioned for the project.
The flexibility analysis shall consider the most severe temperature conditions experienced by the
piping system which may be due to sustained, start-up, normal operation, shutdown, steam-out or
any other upset condition.
Piping flexibility shall be obtained through pipe offset or expansion loops. As far as possible use of
Expansion bellows should be avoided.
The piping system shall be designed to avoid the following:
Piping Stresses in excess of those permitted by the relevant code and standards.
Excessive forces and moments at equipment terminal connections.
Excessive stresses at supporting or restraining elements.
Unintentional disengagement of piping from its supports.
Interface between adjacent lines due to thermal expansion or contraction of the piping
system.
Excessive sag in piping systems, particularly those requiring slopes for drainage.
Special supports requiring complex design details or impractical construction tolerances.
For example, excessive use of spring supports for minor thermal movement (spring support should not be
specified for movements of 3mm or less in Non-Strain Sensitive systems).
Carrying / Supporting pipes from larger diameter headers. This shall be avoided as far as
possible.
Cold spring shall not be used in principle.

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SHEET 5 OF13
DOCUMENT NO. H-156
4.0
4.1
DESIGN CONDITIONS
DESIGN CODE
Stress analysis shall be in accordance with ASME B31.3 (2004).
4.2
DESIGN LIFE
All piping systems shall be designed for a life of 10 years counting for an equivalent number of full
displacement cycles of maximum 7000, unless otherwise required for severe cyclic conditions
4.3
INSTALLATION TEMPERATURE
Installation temperature shall be used only for reaction loads calculations, however the stress range
shall be calculated for difference between the minimum and maximum temperatures, if any
Installation temperature, for all calculation purpose to be considered as below
For cold lines installation temp = 46.70C.
For hot lines installation Temp = 4.4 0C
4.4
FLEXIBILITY TEMPERATURE
Displacement range shall be determined by using the greatest temperature differential imposed by
all operating conditions. For the same reason flexibility temperature to be Design temperature in
the line list. However when necessary maximum operating temperature in lieu of design temperature
can be considered.
Solar temperature of 70C (black bulb temperature 70C) to be considered for analysis purpose for
un-insulated, unsheltered Gas line; if design temperature is less than this temperature.
Design temperatures used for the calculation of liquid line shall be as shown below. They shall be
determined for each segment of piping with the fluid condition taken into account, whether it is
flowing or still.
For piping through which fluid is flowing.
(1)
For piping not heated with tracing or jacket:
The Design temperature specified in the Line Index.
(2)
For piping heated with tracing:

The fluid temperature or 70% of the temperature of heating
medium, whichever the higher.
(3)
For piping being warmed up by bypass line : 70% of the flowing fluid temperature.

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DOCUMENT NO. H-156
For piping in which fluid is still

(1)For piping without tracing
(2)
For piping heated with tracing
70C
:
70% of medium temp.
For Steam out temperature (Applicable Steam Temperature), consideration shall be given to whether
equipment and piping are steamed out simultaneously or separate.
Temperature for internally insulated / lined piping shall be based on heat transfer calculations.
For line connected with pumps, in the stand-by portion of piping without warming by-pass, the
temperature decay shall be considered:
Insta. Temp.
Design Temp.
PUMP A
PUMP A
( standby )
PUMP B
( standby )
Insta. Temp.
Design Temp.
A operation
B stand by
PUMP B
B operation
A stand by
PUMP A
PUMP B
A & B both operating
4.5
FLEXIBILITY PRESSURE
The flexibility pressure shall not be less than the pressure at the most severe condition of coincident
pressure and temperature expected during service, except for occasional variations, where code
limitations shall apply i.e. Design Pressure as indicated in line list.
For Hydro test Condition, reference to be taken from Line list whether hydro test is required or not.
In Stress calculation, Bourdon effect shall be considered for 600 # and Above.
4.6
WIND LOAD
Wind loads shall be considered for pipes with OD 600mm and above including insulation, & above
10m elevation.
Wind loading shall be in accordance with Design Specification for Loads (Doc. No. A-6235-110001).
4.7
EARTHQUAKE
Induced horizontal forces shall be considered and included in the flexibility analysis.
Values for earthquake accelerations are to be taken from Design Specification for SEISMIC (Doc.
No. A-6235-110-007).
The simplified static equivalent method considering only horizontals may be used.

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DOCUMENT NO. H-156
Concurrent wind and earthquake conditions need not to be considered.

4.8
DISPLACEMENTS
Spaces between outside surfaces of two (2) (un) insulated pipes shall be limited to minimum 25 mm
at installation and 0 (zero) mm after displacement, considering the most severe operational
conditions (maximum versus minimum) for both piping systems.
4.9
DYNAMIC ANALYSIS FOR TWO PHASE FLOW

List of lines which is having slug flow (Two Phase Line) to be prepared by process and to be
submitted to OWNER/TEIL for review.
Dynamic analysis to be performed for all two phase lines having slug flow and Transfer lines in the
plant, in order to ensure that such lines are provided with proper supports and there shall be no
vibrations in the line during normal operation as well as during start up or any upset conditions.
Dynamic analysis to be performed at design temperature and operating temperature.
Actual densities shall be considered while carrying out static analysis.
The fundamental frequency of the piping system to be checked to avoid resonance. The minimum
acceptable frequency criteria to be kept as 7 Hz for Transfer lines and 6 Hz for other lines under
dynamic analysis.
Also, report to be submitted for mode shape plots up to 15Hz. model displacement output shall be
submitted. This report should include boundary condition and other parameter used in dynamic
analysis.
4.10
LOADING ON EQUIPMENT
Thrust loads and moments imposed on equipment shall include all loading effects and shall not
exceed the equipment manufacturers recommended values.
Thermal movement at the equipment nozzle shall be obtained from the equipment manufacturer or
calculated with the data known for the equipment.
When acting loadings are over the allowable values, according to the applicable standard or code,
approval shall be obtained from the manufacturer.
In the absence of vendor data, relevant codes like API 610, API 621, NEMA SM23, API560, API661 etc. or
any other approved proven international code/practices NOZZLE LOADING shall be as per TEILs nozzle
loading table attached here with.(Attachment-1)
There is no clear established limit for earthquake loads acting on equipment connections in Codes or
Practices. If calculated loads exceed the standard allowable, engineer considerations shall be taken
or approvals should be obtained from the Mechanical suppliers on an individual basis.
In determining acting loads on vessels connections, local flexibility of vessel walls may be taken
into account, when equipment drawings show that no stiffening other than internal or external vessel
stiffeners is present in the vicinity of the connections.
Local flexibility shall not be used for connections other than perpendicular to a circular vessel wall.
Piping connected to nozzles from vertical static equipment running next to the equipment wall shall
preferably be supported by means of a bracket close to the nozzle to unload the nozzle from weight
and other sustained loadings.

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DOCUMENT NO. H-156
4.11
JOB NO. : 6235

SHEET 8 OF13
FLANGE LEAK CHECK ANALYSIS FOR RELIEF VALVE

Flange leak check analysis for relief valve piping to be performed.
A List of all lines for which flange leakage calculation is required to be prepare by piping dept and
to be submitted for review by OWNER/TEIL.
Reaction forces including both momentum & static pressure effects due to safety valve popping
shall be ascertained in the connected piping according to API RP520 for systems discharging to
atmosphere. The effect of these forces on the piping supports and the anchors of the piping system
shall be calculated to ascertain that the allowable limits at these locations are not exceeded.
System stresses in the inlet and outlet piping portions at safety valves also shall be kept within the
allowable limits, inclusive of the distribution branching points in the inlet portion.
These reactive forces shall not lead to any leakage at the flanged joints present in the system. To
ascertain these necessary calculations for checking leakage at the flanged joints shall be performed.
ASME B31.3 does not describe the evaluation method of flange leakage. Therefore, the force
(tension) and moment at a flange are converted into the equivalent pressure, and added to design
pressure for evaluation. The evaluation for leakage at a flange connection is carried out by following
procedure.
Flange subjected to analysis is selected based on the
following criteria
for 900# and Above
For Safety valve for which Min. pressure

Difference will be 8Kg/cm
F
4.12
ANALOG ANALYSIS
For pulsating lines connected to reciprocating compressors/pumps analog study shall be carried out.
Reports shall include both acoustical and mechanical studies.

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DOCUMENT NO. H-156
JOB NO. : 6235

SHEET 9 OF13
SUPPORT SPAN
Either the stresses or requirements for minimum Natural Frequency of the piping system will limit
the pipe spans.
Stresses due to the sustained loadings and pressure which shall not exceed the basic allowable stress
at temperature, or the maximum deflection due to sustained loadings between two (2) supports
which shall be the lesser of 15 mm or half (0.5) times the outside diameter.
Vertical deflections in piping system in horizontal run between two adjacent supports due to
sustained loading = 3 mm (max) for all steam lines and for all line Longitudinal
expansion/contraction to be limited to 200mm (maximum)

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DOCUMENT NO. H-156
5.0 STRESS CATEGORISATION
Piping route Planed is to be verified in its strength to finalize the piping route. On the premise that
flexibility study shall be carried out for all piping systems, following three methods shall be applied
to verify flexibility in piping system.
Category 1:
Exemption from formal flexibility analysis
Category 2:
Simplified method
Category 3:
Comprehensive analysis
7.0
STRESS CATEGORISATION BASIS
300C
300C AND ABOVE
Non-Ferrous
lines
200C
Line class 900 lb

rating and above
120C
Cold Box,
Aluminum
Exchanger, Air
Cooler, and
Furnace
70C
20C
Rotating
equipment /
Centrifugal Pump
-20C
2 and Above
-60C
Reciprocating
pumps
-120C
2 and Above
-150C
Compressor
-150C AND BELOW
Design Temperature up to
O
O
3 and above
2
3 and above
2 to 4
6 and Above
2 to 4
O
O
6 and Above
2 to 4
Non-metallic lines
6 and Above
Flare headers
8 and Above
Differential
Settlement
Greater Than 50
Mm, From Tank,
Vessel,
Equipment, Or
2 to 6
8 and above

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SHEET 11 OF13
Lines with external

pressure or jacketed
piping
Two phase flow

(slug) / surge
Safety Valve with

pressure difference of
10 kg/cm
Remaining CS / SS
lines
-20C
20C
70C
120C
200C
300C
300C AND
ABOVE
8 And Above
2 TO 4 (Core)
6 And Above (Core)
2 to 4
6 and Above
2 to 6 (Inlet)
8 and Above (Inlet)
Critical line list to be prepared on above points, as well remaining lines to be identified as shown in following Chart
ON NEXT SHEET
Legend :
Stress Category 1
O
-60C
-120C
2 TO 6
-150C
Lines with thermal

cycles greater than
7000
BELOW-150C AND
DOCUMENT NO. H-156
Stress Category 2
Stress Category 3

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DOCUMENT NO. H-156
1)
JOB NO. : 6235

SHEET 12 OF13
For Carbon Steel or Low Chrome Pipe

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SHEET 13 OF13
DOCUMENT NO. H-156
2)
8.0
For Stainless Steel Pipe
STRESS REPORT
The reports shall at least comprise of the following:

- Basic input data and calculated conditions
- Layout isometric and supports configuration including gaps/limit stops
- Calculated member forces and stresses for different load cases
- Forces, moments and displacement reports
- Spring Hangers design parameters
- Additional requirements (reinforcement pad etc.)
- Flange leakage checks if applicable.
- WRC 107/WRC 297 checks.
- Allowable Stress Range.
- Expansion Bellow parameters
- Design calculations for adequacy of supporting elements
- Loads at interface B/L with ISBL/OSBL if any.
- Analysis of segments till nearest anchor at battery limit
- Basis of allowable forces and moments & wherever applicable vendor given allowable
loads/moments.
- Allowable equipment load check
- Codal check

Piping Stress Analysis Engineering

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Total Pages-13

ENGINEERING DESIGN BASIS