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

0

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

ENGINEERING DESIGN BASIS

JOB NO. : 6235

(RESIDUE UPGRADATION AND MS/HSD QUALITY IMPROVEMENT PROJECT)

SHEET 2 OF13

PIPING STRESS ANALYSIS

Table of contents Section

Page

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06

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(RESIDUE UPGRADATION AND MS/HSD QUALITY IMPROVEMENT PROJECT)

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DOCUMENT NO. H-156

1.0

PIPING STRESS ANALYSIS

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

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06

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DOCUMENT NO. H-156

2.4

PIPING STRESS ANALYSIS

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.

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06

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DOCUMENT NO. H-156

4.0

4.1

PIPING STRESS ANALYSIS

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 70°C (black bulb temperature 70°C) 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.

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06

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DOCUMENT NO. H-156

PIPING STRESS ANALYSIS

For piping in which fluid is still (1)For piping without tracing (2)

:

For piping heated with tracing

70°C :

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.

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06

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DOCUMENT NO. H-156

PIPING STRESS ANALYSIS

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 TEIL’s 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.

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06 DOCUMENT NO. H-156

4.11

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PIPING STRESS ANALYSIS

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 •

F

For Safety valve for which Min. pressure Difference will be 8Kg/cm²

M

G

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.

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06 DOCUMENT NO. H-156

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PIPING STRESS ANALYSIS

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)

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06

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DOCUMENT NO. H-156

PIPING STRESS ANALYSIS

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

300°C

300°C AND ABOVE

Non-Ferrous lines

200°C

Line class 900 lb rating and above

120°C

Cold Box, Aluminum Exchanger, Air Cooler, and Furnace

70°C

2”

20°C

Rotating equipment / Centrifugal Pump

-20°C

2” and Above

-60°C

Reciprocating pumps

-120°C

2” and Above

-150°C

Compressor

-150°C AND BELOW

Design Temperature up to

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O O

O

O

O

O

O

O

O

O

O

O

O

3” and above 2” 3” and above 2” to 4” 6” and Above 2” to 4”

O

O

O

O O

6” and Above 2” to 4”

O

O

O

O

O

O

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

O

O

O

O

O

O

O

O

O

O

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06

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Lines with external pressure or jacketed piping

Two phase flow (slug) / surge

Safety Valve with pressure difference of 10 kg/cm²

Remaining CS / SS lines

-20°C

20°C

70°C

120°C

200°C

300°C

300°C AND ABOVE

O

O

O

O

O

O

O

O

O

O

8” And Above

2” TO 4” (Core)

O

O

O

O

O

O

6” And Above (Core)

2” to 4”

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

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

-60°C

O

-120°C

2” TO 6”

-150°C

Lines with thermal cycles greater than 7000

PIPING STRESS ANALYSIS

BELOW-150°C AND

DOCUMENT NO. H-156

Stress Category 2 Stress Category 3

TOYO ENGINEERING INDIA LTD. ISSUED : DATE: Aug.18/06 DOCUMENT NO. H-156

1)

ENGINEERING DESIGN BASIS

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PIPING STRESS ANALYSIS

For Carbon Steel or Low Chrome Pipe

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DOCUMENT NO. H-156

2)

8.0

PIPING STRESS ANALYSIS

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