Professional Documents
Culture Documents
Development of Steam Piping System With Stress Analysis For Optimum Weight & Thermal Effectiveness
Development of Steam Piping System With Stress Analysis For Optimum Weight & Thermal Effectiveness
Development of Steam Piping System With Stress Analysis For Optimum Weight & Thermal Effectiveness
Research Paper
ME- Mech Product Design and Development- pursuing, D.K.T.Es Textile and Engineering Institute,
Ichalkaranji, Kolhapur
2
Mechanical Department, D.K.T.Es Textile and Engineering Institute, Ichalkaranji, Kolhapur
3
Director-Able Technologies India Pvt. Ltd., Pune
ABSTRACT
This report is about the design of steam piping and its stress analysis of a given process flow diagram. The prime objective
of this project is to design the piping system and then to analyze its main components. Wall thicknesses are calculated for all
pipes which were found very safe for the operating pressure. For header pipe the calculated wall thickness is 3.54 mm and
the standard minimum wall thickness is 8.18 mm which is greater than the calculated one by more than 2.3 times. Different
loads such as static loads, occasional loads and thermal loads of all pipes were also calculated. After load calculations,
spacing of supports and designing of expansion loops were carried out. Thermal, static and seismic analysis of main system
pipe has been done and results were compared with ASME Power Piping Code B31.1. After calculation of all applied loads,
pipe components were designed and analyzed both manually and on ANSYS software. The results obtained from both
methods were compared and found safe under available applied loads.
Considering the mathematical model for the piping design, the calculations might suggest an under-designed system vis-vis the relevant CODE. Though, a certain standard exists for a given application, there is enough room to explore the
optimization of design since the projects associated with piping are normally associated with a high quantum of purchase
running in several million rupees to a few billion! Any attempt to rationalize the design would directly improve the savings
for the budgetary outlay for the project work while ensuring safety and addressing concerns for potential claims arising due
to accidents or malfunction of the system.
KEYWORDS- Piping Engineering, Design, Stress Analysis, Expansion loops, CAE software (Ansys)
1] INTRODUCTION
Pipes are the most delicate components in any
process plant. They are also the busiest entities. They
are subjected to almost all kinds of loads, intentional
or unintentional. It is very important to take note of
all potential loads that a piping system would
encounter during operation as well as during other
stages in the life cycle of a process plant. If we ignore
any such load while designing, erecting, hydrotesting, start-up shut-down, normal operation,
maintenance etc, It can lead to inadequate design and
engineering of a piping system. The system may fail
on the first occurrence of this overlooked load.
Failure of a piping system may trigger a Domino
effect and cause a major disaster. Stress analysis and
safe design normally require appreciation of several
related concepts. An approximate list of the steps that
would be involved is as follows.
1. Identify potential loads that would come on
to the pipe or piping system during its entire
life.
2. Relate each one of these loads to the stresses
and strains that would be developed in the
crystals/grains
of
the
Material
of
Construction (MoC) of the piping system.
3. Decide the worst three dimensional stress
state that the MoC can withstand without
failure
More et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
1 Process Design
This process is based on the requirement of the
process variables. It defines the required length &
cross sectional area of pipe, the properties of fluid
inside the pipe, nature & rate of flow in it. These
variables affect the positioning and placements of
equipments during lay outing and routing. The
operating and design working conditions are clearly
defined. The end of Process Plan Design is the
creation of a Process Flow Diagram (PFD) and
Process & Instrumental diagram (P&ID), which are
used in the designing & lay outing of the Pipe.
2 Piping Structural Design
In piping structural design, according to pressure in
pipelines, the design and minimum allowable
thicknesses are calculated; according to the required
codes and standards. ASME codes for various
standards are available, for process fluid flow, ASME
B31.1 (Code for power/steam piping) is used. In the
structural design of pipes, when all the loads are
calculated then the required span is also calculated
for supporting the pipes.
ASME B31.1 covers the minimum requirements for
the design, materials, fabrication, erection, testing,
and inspection of power and auxiliary service piping
systems for electric generation stations, industrial
institutional plants, and central and district heating
plants. The code also covers external piping for
power boilers and high temperature, high-pressure
water boilers in which steam or vapor is generated at
a pressure of more than 15psig and high-temperature
water is generated at pressures exceeding 160 psig or
temperatures exceeding 250F. This code is typically
used for the transportation of steam or water under
elevated temperatures and pressure as mentioned
above, so this is the reason that why this code is
selected for the steam piping system which is
external to the boiler.
Boiler outlet section of the steam system comes
under the category of ASME Code B31.1 Power
piping. In order to ensure the safety of the piping
system, code requirements should be fully satisfied.
For different loads this code incorporates different
relationships for stress level as given below .[]
A] Stresses due to sustained loadings
The effects of the pressure, weight, and other
sustained loads must meet the requirements of the
following equation.
=
Where
.
1.0
10000.75& 10000.75&(
+
+
)
4"#
'
'
Where
Where
f = Stress range reduction factor
( = Range of resultant moment due to thermal expansion,
N-mm
= Allowable stress range for expansion kPa; The rest of
the terms are same to above equation.
More et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
+8
-1234567
Where
-1234 7
=-6
Where
t = specified wall thickness or actual wall thickness
in mm. For bends the minimum wall thickness after
bending should not be less than the minimum
required for straight pipe.
iii) Sustained Load Calculations
Sustained loads are those loads which are caused by
mechanical forces and these loads are present
throughout the normal operation of the piping
system. These loads include both weight and pressure
loadings. The support must be capable of holding the
entire weight of the system, including that of that of
the pipe, insulation, fluid components, and the
support
K
F
GHIIJ - -
KL
4
F
K
Fluid Weight = G QJRS
4
KL
Pipe Weight =
Where
K
KL
Where
More et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
Design Parameters
As already sizing of this piping system has been done
and the available information are;
Number of pipes = 48
Number of junctions = 49
Wind Velocity = 100 miles/hr
4] ANALYSIS:
Thermal, static and seismic loads on pipes and their
analysis along with verification from the code have
been done []
A. STATIC LOAD ANALYSIS
cFor Static loads calculation, considering again same
pipe line and taking its section up to first vertical leg
of the expansion loop. This pipe is to be considering
as a straight beam with uniformly distributed load
(beam) and taking its specification.[r]
As this pipe section is considered as straight beam
with one anchor support & four vertical restraints, so
there are five unknowns in this problem. For solving
this problem, singularity method has been followed
Int. J. Adv. Engg. Res. Studies/III/II/Jan.-March.,2014/108-113
More et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
E = Modulus of Elasticity, psi
I = Section modulus, in
~
Where
n = Displacement absorbed by leg n, in
Ln = length of leg n, ft
Li = length of each leg resisting specified displacement, ft
T = Total displacement to be absorbed, in
+ +
Methodology
For thermal analysis in pipes we will use method of
guided cantilever method, in which thermal load
and moments will be calculated as given
Below
12 | Y
o
6|Y
Moment M =
o
Thermal Load F =
Where
o = 0.75 & 12
1.5
8'
Where
= Thermal Expansion, in
L = Length of segment under observation, in
Int. J. Adv. Engg. Res. Studies/III/II/Jan.-March.,2014/108-113
[r]
More et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974
g = ' Y h
REFERENCES:
1.
2.
3.
5.
7.
4.
Where
0.75& + *
+
4"
'
6.
8.
Where
1.2 14400
2.838 x 103 < 17.280 x 103
It means that the pipe is safe by more 7 times than
allowable limits under the seismic loads.
5] CONCLUSION
Following conclusions are made from the analysis of
the designed system.
The designed pipe verified all the conditions
defined by the ASME Boiler and Pressure
Vessel code B31.1. Thickness and working
pressure calculated are in the safe limit.
Thermal, Seismic and Sustained analysis results
obtained are in the safe limits defined by the
Code.
The analysis shows that the complete system is
safe and the results are verified by manual
calculations and ANSYS software.
On the positive side of the manual calculations
lays the fact that it gives fully basic concept of
the piping system. While the assumptions made
during manual calculations make the results
slightly differ from the software results.
As for thermal analysis is concerned, guided
cantilever method was used and this proved to
be a useful tool for thermal stress loads
calculations.
To do seismic analysis by manual calculations
is really a tough job but static analysis method
was a handy tool to deal it
Int. J. Adv. Engg. Res. Studies/III/II/Jan.-March.,2014/108-113
9.
10.
11.
12.
13.