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Aim of Seminar
To know piping design basics by going through the following points:
Design of pressure components. Pipe Span calculations. Design of pipe supports & hangers. Stiffness & flexibility. Expansion & stresses. Line expansion & flexibility. Supports & anchorage of piping.
Many decisions need be made in the design phase to achieve this successful operation, including: Required process fluid quantity. Optimum pressure-temperature. Piping material selection. Insulation selection (tracing). Stress & nozzle load determination. Pipe support standard.
The codes provide minimal assistance with any of these decisions as the codes are not design manuals.
Pipe Structure static design, not Layout design. Limitations: Code, Pressure, Temperature, How long is the plant lifetime, What is the plant reliability, etc.. Piping designed according to B31.3 has less lifetime than B31.1 due to lower F.S. Reliability of piping under B31.1 should be higher than B31.3 Given that the code is a product of pressure technology, one of the concerns is the pressure-temperature ratings of the components.
Each system be it vessel or piping has some base pressuretemperature rating. This is essentially the pressure temperature rating of the weakest member of the system. This can be translated that no minor component (valve, flange, etc) shall be the weakest link. The key components of the design conditions are the design pressure and the design temperature. Design pressure is defined as the most severe sustained pressure which results in the greatest component thickness and the highest component pressure rating. Design temperature is defined as the sustained pipe metal temperature representing the most severe conditions of coincident pressure and temperature.
Thus we can try to simplify our stresses into two main categories; Pressure stress is the circumferential stress (primary stress) or hoop stress, which is known to be not self limiting. Temperature stress is the shear or bending stress (Secondary stress), known to be self limiting. In addition VIBRATION, has to be addressed as low cycle high stress named as thermal expansion cycles, represented by f=1 for 7000 cycles, otherwise detailed design has to be performed to prove that the pipe will withstand high cycle, low stress loads.
The code assists the designer in determining adequate pipe wall thickness for a given material and design conditions as follows: - Calculate the pressure design thickness t - Add the mechanical corrosion and erosion allowances c to obtain the thickness tm=t+c - Add mill tolerance (MT) to tm, then select the next commercially available wall thickness. - Provided t<D/6, if not high pressure piping equations apply.
where: P = Internal design pressure Do = pipe outside diameter S = the pipe material allowable stress, S is for the listed pipe material at hot temperature E = quality factor Y = stress-temperature compensating factor.
Questions
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Multiple miters are, whose angle of miter cut is less than 22.5 degrees, limited to a pressure that will generate HOOP STRESSES not to exceed 50% of the yield strength of the material at temperature. This is done by restricting the maximum pressure to the lesser value as calculated by equations (4a) or (4b) in the code.
Single miters, or miters whose bend angle is greater than 22.5 degrees is limited to HOOP STRESSES of 20 % of the yield of the material at temperature by equation (4c).
As we usually consider the lesser value of the above calculations, the multiple miter elbow with =22.5, results in maximum allowable pressure to be 455 kPa (66 psig).
The philosophy of the code for intersections is centered around the available pressure reinforcement offered by the geometry of the intersection. The process of making an intersection weakens the run pipe by the opening that must be made in the run pipe. Unless the wall thickness of the run pipe is sufficiently in excess of that required to sustain pressure at an intersection that is NOT manufactured in accordance with a LISTED STANDARD, it is necessary to provide added reinforcement. This reinforcement is added metal, local to the intersection, that is integral with the run and branch pipes
The branch & run angle between 45 and 90 deg. And the axes intersect. The principle is that the area removed by the opening is added or accounted for as added reinforcement or excess area due to thickness above the pressure requirements.
d1 = effective length removed from the run at the branch, d1 = Db or d1 = [Db - (Tb-c) ] / sin
d2 = 1/2 the width of reinforcement zone d2 = greater of d1 or [ (Tb c) +(Th c) +d1/2 ], but less than Dh
L4= height of reinforcement zone = smaller of 2.5(Tb c)+Tr and 2.5 (Th c) Dh: Outside diameter of header Db: Outside diameter of branch th: header pressure design thickness tb: branch pressure design thickness Th: header thickness minimum per purchase or minus mill tolerance Th: nominal wall thickness of header Tb: branch thickness minimum per purchase or minus mill tolerance Tb: nominal wall thickness of branch
Tr: thickness of reinforcement pad c: sum of mechanical (thread & groove), corrosion and erosion allowances : angle between the header and the branch axes
Required area A1 = th.d1.(2 - sin )
A2: excess area in run =(2 d2 - d1) (Th th - c) A3: excess area in branch = 2.L4 (Tb tb c) / sin
4) the centerline axis of the branch intersects the centerline axis of the run.
Branch intersections that do not meet these conditions may be qualified by proof testing or other means specified in paragraph 304.7.2 of the code.
The required percent replaced area within the prescribed reinforcing boundaries depends on the angle of the intersection. This percent required area will range from 100% of the area removed, th.d1.(2 - sin ), for a 90 intersection to about 130% required for 45 intersections.
The strength of an intersection grows increasingly weaker as the branch angle departs from 90. This increasing weakness in strength with decreasing 1 is accounted for by the term (2 - sin ) in the required area equation. The change in required area for decreasing , expressed in percent is illustrated in Figure 13.
Questions
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Pipe Supporting
Pipe Supporting
The objective during the pipe supports design phase is to prevent the following:
overstress of piping leakage at joints overstress of supports excessive forces on equipment excessive interference with thermal expansion excessive pipe sag (especially for piping requiring drain) excessive heat flow, exposing support to temperature outside their limits Etc..
Pipe Supporting
The purpose of pipe supports is to control the weight effects of the piping system, as well as loads caused by pressure thrust, vibration, wind, earthquake, shock, and thermal displacement. The weight effects to be considered shall be the greater of operating or hydrotest loads. The B3 1.3 guidance for pipe support types and materials of construction is presented in the B31 .3 TABLE 326.1 LISTED STANDARD, MSS SP-58. The material selection for clamps and bolts, for example, is of particular importance in elevated temperature service. SP-58 assistance would be in the selection of a clamp material for example in 750F (400C) service. A review of the tables in SP-58 reveal that Carbon Steel clamp material would not be suitable, nor would the common type bolting, ASTM A307 used in clamps. The designer would be guided to use an alloy steel for the clamp such as ASTM A240 and ASTM A193-Grade B7 bolts.
Questions
Selection and design of pipe hangers is an important part of the engineering study. High temperature, high pressure pipes are critical to a point that early in the basic design phase supports locations and loads have to be decided upon. Concentrated hanger loads on structures, buildings and their effect on equipment have to be well known from the very beginning of the project. Basic information has to collected before proceeding with calculations and detailing of pipe supports, as follows; - A complete set of piping drawings - A complete set of steel and structural drawings/ data. - A complete set of drawings showing locations of ventilating ducts, electrical cable trays, equipment locations (pumps, tanks, etc) - A complete set of piping specifications and data. - Insulation specification. - Movement of all critical equipment connections such as boiler headers, steam drums, turbine connections, etc.. - The results of stress, flexibility, and movement calculations performed for critical systems.
Support Design
Restraints (anchors and guides) are provided to direct thermal expansion to areas designed to absorb it and to ensure that expansion joint movements occur in the directions for which the joint is designed. Expansion joint design shall conform to the requirements of Appendix X, which provides guidelines for the design, fabrication and installation of bellow type expansion joints.
Supports elements shall be designed for all loads applied including weight, pressure, wind, earthquakes, friction etc
Hangers Example
Example Problem:
1-Problem Description. 2-Thermal movement calculations. 3-Hanger Load Calculations. 4-Selection of proper hangers.
Hangers Example
Hangers Example
Hanger Supports
The pipe attachment and the structural beam attachment of a rod hanger assembly should allow the hanger to swing to allow for lateral movement of the pipe where there is horizontal pipe expansion. It should be noted that horizontal movement of the hanger will result in a vertical movement as shown previous slide. The subsequent horizontal forces should be checked.
Variable spring hangers are recommended for general use in non critical piping and where vertical movement is small on critical piping. Acceptable practice is limit amount of supporting force variation (difference between hot load and as installed-cold load) to 25% for critical piping systems on horizontal piping. The amount of variation can be calculated by multiplying the spring scale in lb/inch (Kg/mm) by the amount of vertical expansion in inches (mm). The main problem with variable spring hangers is that this variation in load must go somewhere, it is transferred to the nearest restraint or equipment which may cause damage both to the equipment and/ or piping system.
Calculating the variability in accordance with MSS SP-58: Var. = (Hot load Cold load)/Hot load x 100
The load margin between the maximum load, either hot or cold, and the load at the maximum limit of the operating range must also be considered. This load margin should be greater than the weight of the hanger hardware that is supported by the spring, ex. Clamps and hanger rods used to connect the piping to the spring. If the total piping loads plus the load of the supported hanger hardware cannot be accommodated within the spring hangers operating range an alternate spring hanger design should be considered.
This is accomplished by the use of a helical coil spring working in conjunction with a bell crank lever in such a way that the spring force times its distance to the lever pivot is always equal to the pipe load times its distance to the lever pivot. For use when the variation in a variable spring hanger is above 25%. The variation is transferred to the closest restraint or equipment and, in the case of equipment,. This increase in the load and/ or moment on the nozzle may cause structural damage. In such cases a constant load hanger would be selected. Because of its constant load effect the constant support hanger is used where it is desirable to prevent pipe weight load or expansion loads being transferred to connected equipment or adjacent supports or hangers. Therefore they are used for the support of critical piping systems.
Spring Hangers
Returning back to our Example: Difference in effect in using a variable spring as compared to a constant spring support hanger, as per Fig. H-1, page 157. Load for Hanger H-1 was calculated as 5363lb. Vertical movement at H-1 was 2.41 inches up, from the cold to the hot position of the pipe. Amount of variation is 1500lb/in x 2.41in.=3615lb, while the hot load was 5363lb, so as the direction of movement from cold to hot is upward, the cold load is 5363lb + 3615lb, or 8978lb. Pipe weight does not change throughout its cold to hot cycle, while the supporting force varies. Thus the hanger would exert an unbalanced force on the pipe equal to the amount of variation, or 3615lb. Most of this force would be imposed directly on connection A., where limits are established for the force which maybe applied. Changing the spring scale to lower the variability still imposes a high force on A. Appropriate hanger support type for H-1 is a constant support. The hanger will be calibrated to the calculated pipe weight, so its supporting force would be 5363 lb at cold position, and 5363lb also at hot position.
However, the price of a specially designed spring includes engineering and setup charges, and unless a large quantity of a particular size is to used, it is not economical to design special individual springs, and a more prudent approach is to select spring devices which are available commercially.
Vibration arising from pump pulse, compressor and similar conditions is a problem in piping systems. Such conditions can be avoided by use of commercially available spring supports. Systems that respond to exciting vibrations can be controlled satisfactorily by the use of dampening device. There are two general types to consider; the coiled spring and the hydraulic vibration dampener. There are two types of coiled-spring vibration dampeners; the opposed-spring type and the double acting spring type (type50). These types should be arranged so that the springs are in the neutral position during normal operating conditions of the system. The hydraulic vibration control is a unit which operates by means of a controlled flow of fluid through an orifice. Resistance to movement increases with the speed of displacement. One distinct advantage of the hydraulic device is that there is a min. of resistance to thermal movement of the piping. Both spring and hydraulic cylinder devices may be used to control sway and absorb shocks.
In addition to supporting gravitaton loads, the designer must also be concerned with the provision of a suitable system of anchors, guides, restraints, stops, and braces to control intended movement, maintain piping position, and protect equipment from possible excessive loading shock forces. The layout of each system section of piping should be reviewed, taking note of such factors as configuration branches, expansion joints and loops, pipe sizes, terminal connections, relation stiffness of each leg in all planes, and system operating conditions. The digestion of all these factors, coupled with visualization of the normal thermal movement of the system under consideration, enables an evaluation of the specific requirements necessary to assure positive control during all phases of operation.
Anchors and restraints may be required to establish definite movement patterns, counteract thrust forces, or, as in the case of vibration-imposing equipment used to prevent transmittal and possible build-up of vibration throughout the entire system. Specific examples are the need for properly located anchors in a steam distribution system to prevent overloading of the smaller branches, anchors and guides, to actuate and align expansion joints and loops properly, and restraints of fixed points in the vicinity of compressor equipment or quick-closing control valves. Long straight runs or sections of piping that are obviously weak in some plane may require additional guiding or bracing to provide lateral structure stability. As in the case of all applications of anchors and guides, the overall installation must provide sufficient flexibility to accommodate thermal growth. For sections where the movement does not permit the use of rigid struts, guides with sufficient clearance to accommodate the normal movement may suffice by limiting the displacement. Positive strut action can be obtained at points subject to movement through the use of special devices such as hydraulic snubbers.
Is the support to take the entire riser weight, or is this weight to be distributed among several supports? Are the hydrostatic-test conditions more severe than service conditions; that is; will the cold-water-filled condition impose stresses on the support higher than allowable (in cold condition) as compared with hot operating condition and the imposed stresses? When this decision is made, the system erection sequence should be considered and a determination made whether other supports are effective or ineffective during hydrostatic testing.
Guide Supports
Guide Supports
Supports Friction
Restraint Supports
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QUESTIONS
Prismatic member, straight members of uniform cross sectional area. They are the building blocks of structural engineering and also piping software packages. Assuming that the displacements are small, so that shortening of the beam due to bending, may be ignored. Each member has its own local axis which do not coincide with the axis for other members of the structure. It is thus assumed that a force applied in any one principal plane causes displacements in that plane only and that the shear centre coincides with the centroid of the member. There is a possibility of three linear displacements and three rotations at each end of the member. There are thus 12 possible displacement components for each member, or 12 degrees of freedom. Associated with each displacement there is a corresponding force or moment.
The result of the derivation section can be summarized in a single matrix equation for member stiffness as follows; [F] = [K] [X] This is the member stiffness equation, F & X are 12-term vectors of member force and displacement respectively, and k is a 12x12 member stiffness matrix. This is the stiffness matrix for the most general case of a prismatic member in space neglecting shear and with the implicit condition that the deformations are so small as to leave the basic geometry unchanged. Not all structural members require the full 12 degrees of freedom to express their deformations. Since a member in space can have no moments transmitted to it through its hinged ends, its deformation depends only on the three linear displacements at each end, giving it a total of six degrees of freedom. It is important to note the symmetry of the member stiffness matrix k.
The directional cosines matrix can therefore be thought of as the 3x3 rotation matrix Ro. Thus any quantity can be redefined in terms of global axes by pre-multiplying by the rotation matrix. When used to redefine member forces and deflections in structure axes, this process is conventionally referred to as transformation of axes, and the symbol T is used for the transformation matrix. T = [Ro 0 ] [0 Ro]
Basic requirements: Piping systems shall have sufficient flexibility to prevent thermal expansion or contraction or movements of piping supports at terminals from causing; Failure of piping or supports from overstress or fatigue Leakage at joints. Detrimental stresses or distortion in piping and valves or in connected equipment (pumps and turbines for example), resulting from excessive thrusts and moments in the piping.
Specific requirements:
The computed stress range at any point due to displacements in the system shall not exceed the allowable stress range. Reaction forces computed shall not be detrimental to supports or connected equipment. Computed movement of the piping shall be within any prescribed limits, and properly accounted for in the flexibility calculations.
Questions
Which code that applies to system. Design Temperature and Pressure. Material Specification. Pipe Size & wall thickness of each of the piping components. The layout of the system including dimensions and thermal movement of terminal points. Limitations of end reactions on terminal points as given by equipment manufacturers.
The requirements for formal analysis are identical to those of B31.1. The Code gives the following equation (same as B31.1) to check if formal (simplified or comprehensive) analysis is required:
D y / ( L U )2 0.03
D: outside pipe diameter, mm y : resultant of displacement strain, mm L: developed length, m U: anchor straight distance, length of straight line joining anchors, m
Applicable code only will determine the minimum safety requirements for the material at the design conditions of pressure and temperature. Some code specify the modulii of elasticity for commonly used piping materials as well as formulae to determine stress intensification factors and flexibility factors. Codes state that, the piping system shall be treated as whole, in calculating the flexibility of a piping system between anchor points and that the significance of all parts shall be recognized. In addition, calculations shall take into account stress intensification factors which apply to components other than sections of straight pipe.
When two or more PRINCIPAL STRESSES act at a point on a pipe, a SHEAR STRESS will be generated. One example of a SHEAR STRESS would be at a pipe support where a RADIAL STRESS caused by the supporting member acts in combination with the LONGITUDINAL BENDING caused by the pipe overhang.
Cold springing is the intentional deformation of piping during assembly to lower the initial displacement strains in the operating condition. It is used to lower the forces transmitted to connected equipment and to lower the deviation from as-installed dimensions, such as inclination of hangers. However, cold springing does not change the magnitude of stress range. The amount of cold spring C.S. is usually expressed as a percentage or fraction of the total expansion
This center-of-gravity/line-of-thrust concept is further illustrated by the following two computer analysis of the above pipe layouts. Both piping layouts are the same pipe size, temperature, and the anchors are the same distance apart.
The L shape moved the center of gravity, cg away from the line of thrust which produced a lower stress, greater flexibility even though the Z shape had one more elbow.
Questions, Comments