STRESS ANALYSIS TRAINING –

PART II
(ANALYSIS)

BY
Nedunchezhiyan Anbazhagan
TOPICS THAT WILL BE COVERED TOPICS

 1. Checking of Stresses
 2. Checking of Displacement
 3. Checking of Loads – support and nozzle (Welded Storage
tank, Compressor, Pressure vessel, Pump, Air cooler)
 4. Flange leakage check (pressure equivalent method,
ASME section viii)
 5. Trouble shooting.
Basic Parameters to be checked before Analysis

 1. Unit file (.FIL) and Configuration file (.cfg)

 2. Building Load Cases
BASIC PARAMETERS

(i) Basic Load case

(ii) Load case with hanger (Without Wind and Seismic loads)
BASIC PARAMETERS

Stress Specification
(iii) Load case with hanger (With Wind and Seismic loads)
BASIC PARAMETERS
 BASIC PARAMETERS

 3. Load cases Combination Methods

I. Algebraic
II. Absolute
III. Scalar
IV. SRSS
V. MAX
VI. MIN
VII.SIGNMAX
VIII.SIGNMIN

Caesar II User Guide

 STRESS ANALYSIS

 1. Checking of Stresses
Load Case No Load Case Stress Type Analysis Type
Loads Stress
L1 WW+HP (HYD)  
L2 W+T1+P1 (OPE)  Where:
L3 W+T2+P1 (OPE) 
L4 W+T3+P1 (OPE) 
L5 W+T1+P1+U1 (OPE)  W Weight with content
L6 W+T1+P1-U1 (OPE)
WNC Weight No Content

L7 W+T1+P1+U2 (OPE) 
L8
L9
W+T1+P1-U2
W+T1+P1+WIN1
(OPE)
(OPE)


WW Weight with water
L10 W+T1+P1-WIN1 (OPE)  T1 Operating Temperature
L11 W+T1+P1+WIN2 (OPE) 
L12 W+T1+P1-WIN2 (OPE)  T2 Maximum Design Temperature
L13 W+T1+P1+F1 (OPE) 
L14 W+P1 (SUS)   T3 Minimum Design Temperature
L15 WNC (SUS) 
L16 L16=L5-L2 (OCC) P1 Design Pressure
L17 L17=L6-L2 (OCC)
L18 L18=L7-L2 (OCC) HP Hydro test Pressure
L19 L19=L8-L2 (OCC)
L20 L20=L9-L2 (OCC)
U Seismic Load
L21
L22
L21=L10-L2
L22=L11-L2
(OCC)
(OCC)
WIN Wind Load
L23 L23=L12-L2 (OCC) F1 Slug Force
L24 L24=L13-L2 (OCC)
L25 L25=L2-L14 (EXP) 
L26 L26=L3-L14 (EXP) 
L27 L27=L4-L14 (EXP) 
L28 L28=L3-L4 (EXP) 
L29
L30
L29=L14+L16
L30=L14+L17
(OCC)
(OCC)




Sample Stress Analysis Output Check List
L31 L31=L14+L18 (OCC)  
L32 L32=L14+L19 (OCC)  
L33 L33=L14+L20 (OCC)  
L34 L34=L14+L21 (OCC)  
L35 L35=L14+L22 (OCC)  
L36 L36=L14+L23 (OCC)  
L37 L37=L14+L24 (OCC)  
 STRESS ANALYSIS

 2. Checking of Displacement

Pipe sagging
Pipe horizontal displacement

 Ensure that the pipe horizontal displacement is within the

limits so that it does not exceed the distance to the nearby
pipe.
 STRESS ANALYSIS

 3. Checking of Loads – support and nozzle (Welded Storage

tank, Compressor, pressure vessel, Pump, Air cooler)
 CHECKING OF LOADS

LIMITING VALUES OF TERMINAL FORCES AND MOMENTS

Centrifugal pumps : API 610 / ISO 5199

Positive displacement pumps : API 676
Steam turbines : NEMA SM 23
Centrifugal compressors : API 617
Reciprocating compressors : API 618
Air cooled heat exchangers : API 661
Plate heat exchanges : API 662
Shell and tube heat exchangers: : Manf. Specific. (Std.7058)
Fired heaters : Manf. Specific.
Flat bottom welded storage tanks : API 650
 CHECKING OF LOADS

CENTRIFUGAL PUMPS – API 610

EQUIPMENT – ARRANGEMENT AND CO-ORDINATE SYSTEM

END SUCTION SIDE SUCTION TOP SUCTION VERTICAL

TOP DISCHRGE SIDE TOP DISCHARGE INLINE PUMPS
DISCHARGE
CENTRIFUGAL PUMPS – API 610 CHECKING OF LOADS

For nozzle size > 400 Allowable loads are

as per manufacturer std.
However N times the values established in
NEMA SM-23 can be asked from
manufacturer.

API 610 specifies that the pump casing

shall be designed to withstand twice the
forces and moments indicated in table 4.
The piping configuration that produces
loads and moments outside the above
range is also acceptable provided the
conditions as specified in Appendix F of the
above code are satisfied
POSITIVE DISPLACEMENT PUMPS - API 676
NOZZLE: CHECKING OF LOADS

The American Petroleum Institute Standard 676 specifies in clause 2.4 the limiting values for the
Rotary Positive Displacement Pumps with Alloy Steel or Steel Castings at inlet and outlet nozzles as

Allowable external forces and moments

Fx : 75 D Mx : 125 D

Fy : 75 D My : 125 D

Fz : 75 D Mz : 125 D

D - Diameter in Inches

F - Force in Pounds

M - Moment in ft_Pound

Displacement at the nozzle are to be provided by the manufacturer.

Actual forces and moments are conveyed to the manufacturer for verification.
AIR COOLERS CHECKING OF LOADS

For each nozzle, in its design corroded condition, the simultaneous application of the moments and forces shall not exceed
maximum allowable loads ( 3 x API 661 rev 7), as per the following table:
LOADS PER NOZZLE

Nozzle Size Moments Forces

DN (NPS) N×m N
Mx My Mz Fx Fy Fz
50 (2) 450 720 450 3060 3990 3060
80 (3) 1230 1830 1230 6000 5070 6000
100 (4) 2430 3660 2430 10020 8100 10020
150 (6) 6420 9150 4890 12000 15090 15090
200 (8) 9150 18300 6720 17070 40020 24030
250 (10) 12210 18300 7650 20010 40020 30030
300 (12) 15240 18300 9150 25080 40020 40020
350 (14) 18300 21360 10710 30030 50040 50040

The sum of all nozzle loadings on a single header or multi-bundle bay shall not exceed the following values:
∑ Fx ≤ 30030 N ∑ Mx ≤ 18300 Nm
∑ Fy ≤ 60060 N ∑ My ≤ 24390 Nm
∑ Fz ≤ 50040 N ∑ Mz ≤ 12210 Nm
HORIZONTAL AIR FIN COOLERS – API 661 CHECKING OF LOADS

NOZZLE:
PLATE HEAT EXCHANGERS - API 662 CHECKING OF LOADS

Table -1 : Standard service nozzle loading Co –ordinate system

Table 2 : Severe service nozzle loading

PRESSURE VESSELS CHECKING OF LOADS

EQUIPMENT

Stress specification
PRESSURE VESSELS CHECKING OF LOADS

EQUIPMENT

Qualify Nozzle loads

STEAM TURBINES – NEMA SM 23 CHECKING OF LOADS

NOZZLE: ALLOWABLE FORCE AND MOMENTS.

Forces and moments exerted on the nozzle connections are to be with in the two limits defined in NEMA-SM
23

Limit 1 (Individual Nozzle verification)

The total resultant force and total moment imposed on the turbine at the connection should not exceed:
3FR + MR <= 500 Dc
FR : Resultant force at the particular connection, Pounds
: sqrt (FX 2 + FY2 + FZ2)
MR : Resultant moment at the particular connection, ft-Pounds
:Sqrt (MX 2 + MY2 + MZ2)
Dc : Nominal pipe size of the connection, inches
up to 8” : Nominal pipe size above 8” :(16+ Nominal diameter) /3

Limit 2 (Combined Nozzle verification)

The combined resultants of force and moments on the inlet, extraction and exhaust connections resolved at
the centrelines of exhaust connection should not exceed :
2Fc + Mc <= 250 Dc
Fc : Combined resultant of inlet, extraction and exhaust force, Pounds
Mc : Combined resultant moment of inlet, extraction and exhaust & moments resulting from forces, ft-
Pounds
Dc : Nominal pipe size of the connection, inches
up to 9” : Nominal pipe size, above 9” :(16+ Nominal diameter) /3
ATMOSPHERIC STORAGE TANK
CHECKING OF LOADS
CHECKING OF LOADS
For tanks with diameter D > 36 m CHECKING OF LOADS

 In earlier version of API 650 (up to 10th Edition – 2003 with

Addendum-3), it had section P.3 in Appendix-P, which was
based on WRC 297.

 In present version of API 650 (11th Edition – 2007), in

Appendix-P, Section P.3 is Deleted in its Entirety.
- not included in any other section,
- No alternate method suggested.

 This leaves us the option to check nozzle

as per WRC 297 (P.3 was based on WRC 297)
OR
to continue using method as per P.3 of previous version
of API 650.
 CHECKING OF LOADS

 Under section 1.0 Scope of API 650

It is stated that [under clause 1.1.22 of 11th Edition –
2007] “An alternative or supplemental design may be agreed
upon by the Purchaser or Manufacturer.”

 Based on this, we can specify

WRC 297
OR
Appendix P.3 of previous version of API 650
[10th Edition – 2003 with Addendum-3].
 FLANGE LEAKAGE CHECK

 4. Flange leakage check

(I). EQUIVALENT PRESSURE METHOD – KELLOGG FORMULA

4 F 16 M
Peq  
G 2 G 3

Where:
Peq = Equivalent pressure due to external loads
F = Axial force acting on the flange due to the pipe weight and thermal expansion
M = Bending moment acting on the flange due to the pipe weight and thermal expansion
G = Diameter of the gasket that reacts to the load
 FLANGE LEAKAGE CHECK

(II) ASME SECTION VIII

If the total pressure is greater than the maximum pressure of the rating,
according to the ASME Boiler and Pressure Vessel, Section VIII, Division
1, Appendix 2, bolt stress of the flange shall not exceed 1.5 Sm,

where Sm is the allowable stress at the operating temperature with

insulated flanges
FLANGE LEAKAGE CHECK FLANGE LEAKAGE CHECK
 5. Trouble shooting.
Expansion Stresses failure TROUBLE SHOOTING
Stresses within limits after introducing expansion loop
TROUBLE SHOOTING
Lines Connected to Equipments

For this Figure : In this case we need to check the orientation

of nozzle connected to equipment & change it for our need.

Change routing as shown & put LS in line with Centre of

equipment in E-W.
Finger Piperack

For this Figure: If pipe is part of finger rack connected to main

rack, provide Line Stop / Fixed point closest to main Rack.

The guide & LS position on main header and finger rack header
should be such a way that leg of pipe is available for expansion
at “Tee” junction.
Different Types of Expansion Loops
Nozzle loads exceeding allowable TROUBLE SHOOTING
Nozzle loads qualified
TROUBLE SHOOTING
Pump nozzle load failure due to inadequate flexibility TROUBLE SHOOTING
TROUBLE SHOOTING
Pump nozzle loads qualified for routing with adequate flexibility
TROUBLE SHOOTING
TROUBLE SHOOTING
 Some Preferred routing to be followed
PREFERRED ROUTING
Criteria for the location of supports and guides on
vertical columns and vessels PREFERRED ROUTING

L1 is the minimum length necessary to permit the thermal

expansion of the vertical pipe, its maximum value may be
found by using the values of maximum permitted spans.

NPS 2” ÷ 3” 4” ÷ 6” 8” ÷ 14”  16”

L (m) 3÷4 6÷8 12 ÷ 16 From stress analysis calculations

47
 PREFERRED ROUTING

 TYPICAL LAYOUT
 The piping layout shall be designed considering the vertical thermal
movement. The lines shall be flexible enough to absorb the vertical
movement and to avoid spring support see Det. “B”
 For high temperature of piping connected to large towers, or reactors, it is
necessary to consider the transitory temperature between equipment and
pipe, during the shut down the pipes cooling is more quickly than tower or
reactor See Det. “C”

DET.”B”

48
Pump Piping Supports Arrangements. PREFERRED ROUTING

 In some case it is necessary to change the nozzle orientation in

order to get more flexibility

pumps pumps

vessel vessel

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THANK YOU