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Prof.P.R.RAMANATHAN

HANDBOOKFORPIPINGSTRESSANALYSIS

JAYARAMCOLLEGE OF ENGINEEERING AND TECHNOLOGY

ApprovedbyAICTE,NewDelhi

(AnISO9001:2000Certified&NBAAccreditedInstitution)

Karatampatti

Pagalavadi,Thuraiyur

(Tk)

TIRUCHIRAPPALLI 621014

Preparedby:

J.MohanKumar

N.Panneerselvam

C.Prakash

P.Sivanantham

D E P A R T M E N T O F M E C H A N I C A L E N G I N E E R I N G


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CONTENTS

Module1: OPTIMIZATIONOFPIPEROUTING

Module2: TYPESOFBEND,TEE,NOZZLE&REDUCER

Module3: TYPESOFANCHOR,HANGER,RESTRAINTS

ANDSUPPORTS

Module4: PIPINGDESIGN

Module5: STRESSANALYSISBYFINITEELEMENT

METHOD

Module6: STRESSANALYSISBYCPROGRAMMING


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MODULE1

OPTIMIZATIONOFPIPE

ROUTING


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1.1

Shorter,

Medium&Longerbend


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1.2

Location

ofTees


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1.3

PiperoutingforThermalRun1


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1.4

Pipero

utingforThermalRun2


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1.5

Pipero

utingforWeightRun1


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1.6Pipero

utingforWeightRun2


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1.7

Pieroutin

for3D


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1.8

PiperoutingforFinalRun


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1.9PieroutingforMovementCalcula

tion


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1.10PiperoutingforLoadCalculation


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MODULE2

TYPESOFBEND,TEE,

NOZZLE&REDUCER


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2.1Typesofload

SustainedLoad

Weightofpipewithflange,valves,

insulationandfittingsatnormalworking

conditions.

OccasionalLoad

Duetofluidtransity,waterhammerwind

andseismicininfrequencyinterval.

PrimaryLoad

Stressofsustainedloadandoccasional

loadisknownasprimaryload.

SecondaryLoad

Duetoexpansionandcontractionofpiping


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2.2Typesofstresses

Stressduetosustainedload=0.72Sy

Stressduetooccasionalload=0.80Sy

Stressduetoexpansionload=E [T2 T1]vSh

2

Syminimumyieldstrengthofthe

material

EYoungsmodulus

coefficientoflinearexpansion

T2maximumtemperature

T1 minimumtemperature

vPoissonsratio

Shhoopstress

iistressintensityfactoratinplane

io stressintensityfactoratoutplane

mibendingmomentatinplane

mo bendingmomentatoutplane

ZSectionmodulus

MtTorsionalbendingmoment


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2.3StressintensityfactorandFlexibilityfactor

StressintensityfactorisdefinedastheratioofthemaximumstressintensitytotheNormalstress

S.No DescriptionStressintensityfactor Flexibility

factorii io

1Weldingelbowpipe

bend

0.9/ 0.75/ 1.65 2

Closelyspacedmiter

bend

0.9/

0.75/

1.52/

3Widelyspacedmiter

bend 0.9/ 0.75/ 1.52/ 4 WeldingTee

34 14 0.9/ 15 ReinforcedTee

34 14 0.9/ 16 UnreinforcedTee 34 14 0.9/ 17 Reducer 1 1

8 Buttjoint 1 1

9 Filletweld 1.3 1

10 Weldneckflange 1 1

11 Sliponflange 1.2 1


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12 Socketweldflange 1.3 1

13 Lapjointflange 1.6 1

14 Threadedflange 2.3 1

15 Corrugatedstraightpipe 2.5 5

Bendcharacteristicsh=4.05t/r

2.4TypesofBend

Bend

Shortradiuselbow Radius>3Diameter

Longradiuselbow Radius=1.5Diameter

Bend Radius=Diameter


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2.5TypesofTees

Tee

EqualTee

Diameterofmainpipe=

diameterofbranchpipe

UnequalTeeDiameterofmainpipe

diameterofbranchpipe

ReinforcedTee

2.6TypesofNozzle

Nozzle

Planenozzle

Nozzlewithreinforcedpad

Nozzlewithbackingring

2.7TypesofReducer

Reducer

Concentricreducer

Eccentricreducer


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MODULE3

TYPESOFANCHOR,

HANGER,RESTRAINTS

ANDSUPPORTS


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Thermalstress:

ThermalrunisusedtofindouttranslationandrotationofpipingTranslation(mm)

Dx

Dy

Dz

Rotation(rad)

Rx

Ry

Rz

Primarysupports

AnchorResistbothtranslationandrotationof

piping

Mainanchor Resistmomentinbothdirection

DirectionmainanchorResistmovementinonedirectionand

allowsinotherdirection

InsertinganchorDividesthepipingintoindiexpanding

section

ClampResistthetranslationandallowsthe

rotation

Guide Resisttherotationandallowsthetranslation

LimitstopReduceanchorandreducestresses


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x

y

z

Translationdoubleacting

x

yz

Translationdirective

x/2

y/2

z/2

Translationdirectivebilinear

hx

hy

hz

Rotationaldoubleacting

Rx

RyRz

Rotationaldirective

Rx/2

Ry/2

Rz/2

Rotationaldirectivebilinear


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Weightrun

WeightrunisusedtofindoutforcesandbendingmomentinpipingForces(N) Fx

Fy

Fz

Bendingmoment(Nm)

Mx

My

Mz

Secondarysupports

Lessverticalmovement

LesshorizontalmovementRoller

Lessverticalmovement

MorehorizontalmovementSwingingrod

Moreverticalmovement

Lesshorizontalmovement Trolly

Moreverticalmovement

MorehorizontalmovementSimplerodhanger


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Supports Tocarryhorizontalload

Bracket Tocarryverticalload

LugplateTocarrybothvertical

loadandhorizontalload

Carrierplate

Restraint Towithstandshockload


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Finalrun

TofindoutstressesinpipingBending

stressTorsional

stressStressintensity

factorAllowable

stressCodestress

Ratio

Variableloadhanger

Toresistgravityforceand

movementofpipingfromcold

portiontohotportionwith

25%

Constantloadhanger

Toresistgravityforceand

movementofpipingfromcoldportiontohotportionwith0%

Snapper Towithstanddynamicload

HingedexpansionjointToresistangularrotationinone

plane

CimbalexpansionjointToresistangularrotationinany

plane

Swingingexpansionjoint

Toresistangularrotationinone

planeandtransverse

movement

PressurebalancejointToresistangularrotationinany

planeandtransversemovement

Simple,DoubleandUniversalexpansionjoint

Toresistangularrotationinany

plane,transversedisplacement

&axialmovements.


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Supportspanwithrespecttomaterials

Steel

Pipesize(inch) Span(feet)Water Steam,GasorAir

4 14 17

6 17 21

8 19 24

12 23 30

Aluminium

Pipesize(inch) Span(feet)

4 9

6 10

8 11

10 11.5

Copper

Pipesize

(inch)

Span

(feet)

4 13.5

6 15.5

8 17

10 20


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Spanlimitations

Stress Deflection

Simplysupportedbeam 0.33 22.5

Fixedbeam 0.4 13.5

IMomentofinertia

ZSectionmodulus

LAllowablespan

ShAllowabletensilestress

Allowabledeflection

EYoungsmodulus

WWeightofpipe


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MODULE4

PIPINGDESIGN


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DESIGNOFBOILERCOMPONENTS

4.1 DesignofPipingQ=AV

4 2

4.2 Pressurelossinpiping4.2.1 Pressurelossinincompressiblefluid

Horizontalpipe

2

VerticalorChangeinelevationpipe

2

4.2.2 Pressurelossincompressiblefluid

17.8 100

QDischarge

vVelocity

AArea

toDesignthicknessofpipe

PDesignpressureorTestpressure

d0Outsidediameter

aDesignFactor0.6Forworkingpressure

0.9Fortestpressure

fMaximumyieldstress

eWeldefficiency

0.8forfieldweld

0.9forshopweld

1.0Forseamlesspipe

CCorrosionallowance

lLengthofpipe

dInternaldiameter

Specificweight

gAccelerationduetogravity

hSlantheight

Frictionfactor

dvdensityratio

uCompressibilityfactor

Coefficientofresistance


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4.2.3 Pressurelossinvalvesandfittings

2

4.3 CalculationofTemperaturedrop

tsTemperatureofmediumatthe

startingpoint

tftemperatureofmediumattheendof

pipe

taAirtemperaturesurroundingthepipe

lLengthofthepipe

QHeatlossofthemedium

WWeightofhotmedium

Cpspecificheatofthemedium


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4.4 ThicknessofInsulationinpipingForstillairconditions

log 0.548 1.957

Underwindconditions

log

0.548 1.957 196.85 6868.9

QTotalheatflow

tsTemperatureofoutersurface

tatemperatureofambientair

toOperatingtemperatureofpipe

Surfaceemittance

r1Innerradiusofinsulation

r2Outerradiusofinsulation

kThermalConductivity


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4.5 DesignofBoilercomponents

4.5.1 PipeofSuperheater,Economiser&Riser

IBR338

2

4.5.2 Designofheaderdrum

Designofdrum

IBR2510

2 0.03 0.03

TMinimumThickness

DOutsideDiameter

e 1mmforworkingpressureupto70kg/m2

0.9mmforworkingpressureabove70kg/m2

fPermissiblestress

fPermissibleworkingstress

ELigamentefficiency

TThicknessofshelldrum

DMaximuminternaldiameter


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Dishedend

IBR2518

2 0.1

4.6 Designof ValvesForsteam

51.5 Forair/gases

1.175 Forliquids

38

A1Orificearea

RRequiredcapacityofair/gases

wRequiredcapacityofsteam

VLRequiredcapacityofliquid

PgAbsoluteinletpressure

PLRelievingpressureBackpressure

TgInlettemperature

hSpecificgravity

ZCompressibilityfactor

CgImperialgasconstant

nIsentropicexponent

DOutsidediameter

F=1forendplateswithouthole

F=1.5forendplateshavinghole

u=Factordependupontheratio


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4.7 Designofflanges

Pipeforce

Annularsurfaceforce

4 Totalforce

Installationforce

Swicehaultforce

Boltforce

FpCapacitycorrectionfactorfortheeffectsof

lowselfpressure

Fb Capacitycorrectionfactorfortheeffectsof

backpressure

Fv Capacitycorrectionfactorfortheeffectsof

viscosity

Fw Capacitycorrectionfactorfortheeffectsof

backpressure(liquidsonly)

Fsh Capacitycorrectionfactorfortheeffectsof

superheat

KdiDearatedcoefficientofdischarge


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SectionModulus

Weldneckflange

4 2 4 ForpipesbelowNB500

ForpipesNB500andabove

Plateflange

4 2 2 Flangedesign

k0Gasketcharacteristics

kGDeformationresistanceforce

u1Gasketcharacteristics

SgFactorofsafety

forsoftgasketSg=1.5

softmetalgasketSg=1.4

completemetallicgasketsSg=1.3

0Frictionfactor

9.81conversionfactor

g9.81

lLength

kVibrationsynchronizingfactor


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MODULE5

STRESSANALYSISBY

FINITEELEMENT

METHOD


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STRESSANALYSISBYFINITEELEMENTMETHOD

5.1Symbols

BINP BranchIntersectionPoint

B Branch

FA FlexibleAnchor

A Anchor

TINPTangentIntersection

Point

N Nozzle

CLH ConstantLoadHanger

VLH VariableLoadHanger

C Component


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5.2StressanalysisbyFEM[Routing1]


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

001 01 01 A 0 +10 +5 100 10

010 01 01 T 0 +10 0 100 10

020 02 02 01 T 0 +10 0 100 10

030 02 02 01 T 0 +10 6 100 10

040 02 03 T 0 +10 6 100 10

050 02 03 Ti 0 +10 13 100 10

060 02 03 N +8 +10 13 100 10


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

070 01 04 T 0 +10 0 100 10

080 01 04 Ti +10 +10 0 100 10

090 01 04 FA +10 +2 0 100 10

100 02 05 T 0 +10 6 100 10

110 02 05 Ti 0 +15 6 100 10

120 02 05 FA 9 +15 6 100 10


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

001 01 01 A 0 +10 +5 100 10

010 01 01 T 0 +10 0 100 10

020 02 02 01 T 0 +10 0 100 10

030 02 02 01 T 0 +10 6 100 10

040 03 03 02 T 0 +10 6 100 10

050 03 03 02 T 0 +10 13 100 10


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

060 03 04 T 0 +10 13 100 10

070 03 04 Ti 0 +10 21 100 10

080 03 04 C +9 +10 21 100 10

090 01 05 T 0 +10 0 100 10

100 01 05 Ti 0 +15 0 100 10

110 01 05 Ti +10 +15 0 100 10

120 01 05 FA +10 +2 0 100 10


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

130 02 06 T 0 +10 6 100 10

140 02 06 Ti 0 +15 6 100 10

150 02 06 Ti +10 +15 6 100 10

160 02 06 FA +10 +2 6 100 10

170 03 07 T 0 +10 13 100 10

180 03 07 Ti 0 +15 13 100 10

190 03 07 Ti +10 +15 13 100 10

200 03 07 FA +10 +2 13 100 10


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

001 01 01 A 5 +15 0 100 10

010 01 01 Ti 0 +10 0 100 10

020 01 01 T 0 +10 0 100 10

030 02 02 T 0 +10 0 100 10

040 02 02 Ti 0 +10 +10 100 10

050 02 02 Ti +15 +10 +10 100 10

060 02 02 T +15 +2 +10 100 10


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

070 02 03 01 T 0 +10 0 100 10

080 02 03 01 Ti 0 +10 10 100 10

090 02 03 01 Ti +15 +10 10 100 10

100 02 03 01 T +15 +2 10 100 10

110 02 04 FA +15 +2 +13 100 10

120 02 04 T +15 +2 +10 100 10


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NPTo

BINP

On

Branch

From

BINP

Natureof

attachmentX Y Z T

130 02 04 T +15 +2 +10 100 10

140 02 04 FA +15 +2 +7 100 10

150 03 05 FA +15 +2 7 100 10

160 03 05 T +15 +2 10 100 10

170 03 06 T +15 +2 10 100 10

180 03 06 FA +15 +2 13 100 10


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MODULE6

STRESSANALYSISBYC

PROGRAMMING


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STRESSANALYSISBYCPROGRAMMING

6.1Ruleforconvertingsymbolintosupport

S.No Symbols Name Degreesoffreedom

Nature

1 AnchorSixDOF

arrested

Fixed

support

2Flexible

anchor

FourDOF

arrested

Fixed

support

3 TangentTwoDOF

arrested

Simple

support

4 NozzleTwoDOF

arrested

Simple

support

5 ValveTwoDOF

arrested

Simple

support

6Constant

loadhanger

TwoDOF

arrested

Simple

support

7Variable

loadhanger

TwoDOF

arrested

Simple

support

8 Freeend AllDOF

relievedFreeend


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6.2TreemethodforroutingNo.1


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53/59



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6.5CalculationofHydroweight,Metalweight,Insulationweight&Totalweight

Hydroweight

Metalweight

4 Insulationweight

4 Totalweight

Tw=Hw+Mw+Iw

WeightofUDL=

dInsidediameter

DOutsidediameter

D1Outsidediameterofinsulation

1densityofsteam

2densityofmetal

3densityofinsulation


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6.6PrimarystressanalysiswithrespecttoVibration

Momentofinertia M Distancebetweenneutralaxisandtopmostfibre Bendingmoment

M 22 forcantileverbeam

M 2

8 forsimplysupportedbeam

M 92128 forM 224 forfixedbeam

Bendingstress


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3

8

48

5384

3

192

384

3


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Frequencyofvibration

0.4985

0.4985 1.27

Frequencyofvibration Factorforvibration

Low a1

Medium a2

High a3

w1=wxa1ora2ora3

2 8

9128 24

Stresswithrespecttovibration


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6.7SecondarystressanalysiswithrespecttoHeatTransfer

6.7.1Forcedheattransferduetosteam

Pr

1

6.7.2Heattransferduetoconduction

1 2121126.7.3Forcedconvectionoffluegases

Pr


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1

TotalheattransferQ=Q1+Q2+Q3

Totalheattransfer Factorforheattransfer

Low b1

Medium b2

High b3

w2=w1xb1orb2orb3

Secondarystresswithrespecttoheattransfer

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