Piping Flexibility & Stress Analysis

Course Description

Pipe Stress Analysis is an intensive five-day course designed to give a through understanding of basic and advanced concepts of process piping stress and flexibility analysis as per ASME B31.3. Stress Analysis is a critcal component of piping design through which important parameters such as piping safety, safety of related components and connected equipment and piping deflection can be addressed. It needs good understanding and background in piping layouts, ASME Code requirements and piping design.

Piping Stress Analsis involves examining the flexibility and stiffness of a particular piping system under different loading conditions. Piping stress analysis determines the maximum stresses, displacements, force and moments at restraints and suggests necessary modifications for satisfying the ASME Code Requirements for limits of sustained, displacement and occasional load allowable stresses.

Stress analysis helps revising te piping layout and its supports to avoid high local stresses. The course will discuss different types of stresses affecting piping flexibility, code criterions, and methods of analysis, including simple and comprehensive methods and computerized methods.

The extensive use of case studies and practical exercises during the course of the discussion ensures as comprehensive coverage of the topic as possible.

All the pipe stress analysis concepts will be examined and demonstrated through pipe modeling using pipe stress analysis software to give a detailed insight into the analysis methods and solutions.

Course Objectives

Upon completion of this course, attendees will be able to:
Apply the piping system stress analysis requirements of ASME B31.3 to process plant piping systems
Understand how to perform piping flexibility and stress analysis
Provide solutions to piping loads
Limit piping stresses within the code allowable limits

Note
Demonstration software of stress analysis will be given to participants during the training session, thus a LAPTOP is COMPLUSORY

Course Outline

Module 1 - Stress World Definitions

• Piping Failure Modes
• Why Stress Analysis
• Pipe Stress Engineer Scope of Work
• Force,Moment and Equilibrium
• Different Forces on Piping System
• Stress & Strain
• Stress - Strain Curve (Typical Behavior of Material)
• Modulus of Elasticity, Yield Strength, Ultimate Tensile Strength, Allowable Stress (at "hot" and "cold" conditions, that is, Sh and Sc)
• Code Tables for Allowable Stresses
• Stress (Axial, Shear, Bending Longitudinal Stress due to pressure, Torsion Stress, Hoop Stress, Displacement Stress, Reaction Force)
• Piping Systems Classification (Hot, Cold and Cryogenic)
• Installed and Operating Temperatures
• Fatigue
• Stress Analysis General Working Procedure

Module 2 - Failure Theories

• Maximum Principal Stress Theory
• Maximum Shear Stress Theory

Module 3 - Stress Categories

• Primary Stresses
• Secondary Stresses
• Peak Stresses
• Basic Stress Intensity Limits

Module 4 - Classification of Loads and Code Requirements

• Sustained Loads
• Displacement Loads
• Occasional Loads
• Pipe Loading Chart
• ASME B31.3 Process Piping Code Requirements - Limits of Stresses due to Sustained Loads, Displacement Loads & Occasional Loads
• Allowable Stresses (Time Independent and Dependent Stresses)
• Local Stresses
• Basic Solutions to all Piping Loads

Module 5 - Types of Pipe Loading Conditions

• Internal Pressure Stress
• Axial, Hoops and Radial Stresses
• Weight Stress
• Bending Load due to weight
• Bending Stress and Moments due to weight of pipe
• Hydro Test Load
• Thermal Expansion Loads (Thermal Modes, Free Thermal Expansion, Imposed Thermal Movements, Temperature Decay, Stress Rangers)
• Occasional Loads (Seismic, Relief Valve Discharge, Wind, Steam/ Water Hammer)

Module 6 - Methods of Analysis

• Simplified Analysis (Check as per ASME B31.3)
• Comprehensive Methods of Analysis (Chart and Nomographs)
• Computer Analysis (Static & Dynamic Loads and Analysis Types)

Module 7 - Simplified Analysis

• Simplified Weight Analysis
• Simplified Thermal Expansion Analysis
• Guided Cantilever Method
• Thermal Movement Calculation
• Simplified Seismic Analysis

Module 8 - Layout Solutions for Weight, Thermal, Vibration and Wind Loads Using Nomo Graphs

• Layout Solution for Weight Stress - Continuously Supported and Branch Pipe Allowable Spans
• Solving Concentrated Loads and Reducing Loads on Equipment Nozzles
• Layout Solutions for Thermal Load using force and Stress Nomographs for Pump and Vessel Piping
• Checking Piping Layout in Pipe Racks
• Checking Piping Layout for Reciprocating Equipment
• Checking Piping Layout for Wind Load

Module 9 - Computer Programs and Analysis Methods

• CAESAR - II, CAE PIPE, AUTOPIPE, TRIFLEX
• Capabilities
• Method of Analysis
• Minimum Required Load Cases for Computer Analysis
• Data Required for Stress Analysis

Module 10 - Supports and Restraints

• Functions and Selection
• Supports (Rigid and Flexible Support Types)
• Restraints (Different Types)
• Support/ Restraint Selection Example
• Hanger Selection Example
• Maximum Support Spacing Based on Weight, Deflection and Natural Frequency Criteria
• Support Spacing Criteria
• Function of each type of Restraints with Example Piping Layouts
• Loads on Supports
• Dynamic Supports (Sway Braces and Snubbers)
• Stress Support Symbols
• Locating Supports
• Standard Pipe Support Spans
• Pipe Span Reduction Factors
• Guide Spacing for Wind Loading

Module 11 - Piping Thermal Flexibility

• Introduction and Purpose of Flexibility
• What are we trying to achieve
• Approach for Piping Flexibility and Support Design
• Formal Analysis Requirements (Guidelines Whether to Perform Thermal Flexibility)
• When Detailed Analysis is Needed
• Critical Line List
• Required Design Conditions for Piping Flexibility Analysis
• Piping Flexibility Temperatures
• Thermal Fatigue and Cycles to be Considered
• Providing Additional Flexibility
• Cold Spring
• Types of Flexibility (Axial and Bending)
• Piping Displacement Calculation
• Actual and Free Thermal Expansion Calculation
• Temperature Range Examples
• Expansion Stress and Reaction Force Calculations
• Flexibility and Stress Intensity Factors
• SIF Calculations for Piping Components
• Discussion on Effect of SIF on Piping Stress
• Elbow Flexibility
• Expansion Loops (Types, Sizing, Locating Supports)
• Leg Required for Flexibility
• Initial Anchor Movements/ Nozzle Thermal Growth Calculations

Module 12 - Sustained and Displacement Load Analysis

• Sustained Load Analysis (Calculation Methods and Acceptance Criteria)
• Loads and Design Criteria
• Pressure Stress
• Weight Stress
• Weight Bending Moments
• Allowable Stress
• Displacement Load Analysis (Calculation Methods and Acceptance Criteria)
• Loads and Design Criteria
• Effect of Friction
• Displacement Stress Range Calculation
• Allowable Stress Range
• Considerations for Displacement Analysis
• Example Analysis Discussion
• Fixing Problems
• Flexibility Analysis Examples using Kellog Charts, ITT Grinnel Charts

Module 13 - Nozzle Loads - Piping Stresses and Effect of Piping on Equipment

• Load Limitation on Equipments (Rotating and Stationary)
• What are Equipment Nozzle Loads
• The Piping Effect
• Factors that Affect Nozzle Loads
• Reducing Loads on Equipment Nozzles
• Typical Piping Layout

Module 14 - Expansion Joints

• Introduction
• Types, Application and Selection
• Pressure Thrust

Module 15 - Piping Vibrations

• Introduction
• Analyzing Vibrating Pipe
• Required Natural Frequency of Piping, Frequency Calculation
• Pipe Supports for Vibration. Supports for Pulsation Dampeners

Trainer Profile

MD. Kamal Uddin Ahmed, B. E. (Mechanical Engineering) is a Senior Piping & Pipeline Engineer with 15 - 20 years of progressive & extensive international experience. He is an expert in Process, Power Piping & Liquid & Gas Transmission Pipelines as per ASME & API standards including ASME B1.1, B31.3, B31.4, B31.8, & API 570.

He is a dynamic speaker & master trainer providing knowledge transfer effectively with interactive style that connects with the audience.

He has designed & presented piping design seminars to piping engineers & designers across India, Qatar and Saudi Arabia. He has trained more than 1500 mechanical, chemical, & petroleum engineers in Piping Engineering, Pipiline Design, HVAC & Plumbing Systems from different countries including India, Qatar, Saudi Arabia, Jordan, Turkey, Sudan, Ghana, Nigeria, Maldives, United Kingdom, and Thailand.

Throughout his career, Md. Kamal has been providing these expertise for both new and operating process/ power plants and facility construction industry using codes/ standards, software analysis and field experience in arriving at safe, economical piping designs and solutions to piping problem.

Besides, he has also offered his services such as Project Management, Design/ Analysis and Construction/ Testing/ Inspection in India and Kingdom of Saudi Arabia involving many onshore and offshore projects.