TC Technical Community - Global G-P-PI 270

Procedure
Piping
Page 1 of 10
Piping Flexibility and Stress Analysis
Issue Sep 2011
Flexibilitäts- und Spannungsanalyse in Rohrleitungen Supersedes
RPI 65 Anlage 5.1.1:2003-12
G-P-PI 270:2007-01

Contents
Page

0 Preface 2
1 General 3
2 Workflow 3
3 Selection of the calculation method 4
4 Details of calculation and documentation 7
4.1 General 7
4.2 Computational flexibility and stress analysis 7
4.3 Simplified method 8
5 References 10
6 Annex 10
© 2011 BASF

Published: 7 Intranet 7 Extranet For internal use only

Technical Rules BASF g-p-pi_270_en.doc / 13.10.2011
G-P-PI 270 Sep 2011
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0 Preface
0.1 Objective
This procedure provides the requirements for the assessment of piping systems to determine when a piping
flexibility and stress analysis should be performed. Specific requirements for the stress analysis scope and
procedures are given in the Codes and Standards referenced in this procedure.
This technical rule shall assist the user in efficiently dealing with the tasks set and achieving economically and
technically approved solutions.

0.2 Validity Area

BASF Group

0.3 Commitment & Group of Users

This technical rule is intended to be applied by BASF employees and contractors as applicable. While it provides a
field-tested solution, alternative specifications shall be acceptable.
While complying with this BASF-Procedure is essential it shall be without prejudice to compliance with relevant
statutory requirements.
If applicable, mandatory application of this technical rule to relevant supplies and third-party services shall be
specified by the requisitioner in contracts/purchase orders/specifications. Alternatives shall then not be acceptable
any more.

0.4 Responsibility for Content & Updating

Committee:

G-CT Technical Expertise

Author / Contact:

Limpert, Rolf GTE/BE - Piping

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1 General
A formal stress analysis shall be performed by simplified or computer assisted (computational) methods. It is the
responsibility of the Stress analyst and Piping Lead Engineer of BASF to determine the extent and method of
analysis used.

2 Workflow
All lines should be supported and routed to be flexible enough so that no overstressed areas are created in the
piping and attached equipment. This is most efficiently achieved during the piping design stage by proper pipe
routing and support. After completion of the preliminary pipe routing design, each system shall be analyzed to
assure that it conforms to the Code requirements.
During the planning the following process should be used:
1. Route the pipe within the plant considering:
a. equipment arrangement
b. process conditions (e.g. free-draining, two-phase flow, pressure loss)
c. existing pipe racks /supports and,
d. temperature-dependent required compensating lengths
2. Locate initial supports and perform a check of support spacing and pipe spans per the method according to
Annex 1.
3. If a flexibility analysis is necessary, determine if a simplified or computational formal stress analysis should be
performed (see Figure 3 in Section 3 of this procedure).
The simplified flexibility analysis method given in Annex 1 Section 3 is very conservative since the inherent
flexibility of bends in the system is not considered. When calculations using the simplified stress analysis method
show that sufficient flexibility is not provided according to Annex 1 Section 3, one or a combination of the following
must be done:
4. Optimize the pipe supports concerning arrangement of anchors, guides and vertical stops. If necessary use of
spring cans/hangers or supports with gap.
5. Perform a computational stress analysis.
6. Increase the flexibility of the piping system by adding bends/changes of direction.
7. Expansion joints/flexible connectors and spring hangers/cans shall be used only when it is not feasible to
provide flexibility by other means and generally only after the results have been confirmed by a computational
stress analysis (see Section 4.2.2).
An additional disadvantage of the simplified-method shown in Annex 1 is that it does not determine the loads
imposed by piping on attached equipment or anchors. Piping designed according to Annex 1 can be assumed to
cause no overstressed areas when connected to pressure vessels, but provides no detail information about loads
imposed on other types of equipment. More detail calculations may also be necessary to resolve the equipment
reaction due to other loadings (e.g. swelling load, earthquake, wind/hurricane loading). In all cases where
equipment loadings must be evaluated against published allowable, they must be determined by computational
stress analysis method.
Anchor points (either in the piping or between piping and equipment), shall not be in line with one another: at least
one change of direction must be installed (exception: plastic lines).
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3 Selection of the calculation method

In accordance with the following diagrams a flexibility analysis for metallic piping has to be performed
The diagrams determine whether the piping should be checked by a detailed computational flexibility and stress
analysis, a simplified stress analysis, or if no check is needed. The diagrams are based on sample calculations,
views of economy and empirical values. They result in a first reference whether or how the piping should be
checked. The exact definition of the proceeding must be determined by experienced personnel, since the diagrams
do not take all specific situations into account. In no case shall the maximum (or minimum) temperature be higher
than allowable for the used material.
The diagrams are applicable for analysis of jacketed piping using the outer jacket pipe diameter.
Additional requirements:
For high-pressure pipes PN > 160 (2500 psi) and nominal sizes DN > 25 (1") with maximum allowed temperatures
>60°C (140°F) or <-40°C (-10°F) within the area “No Check required” a simplified pipe stress analysis has to be
performed.

Austenitic Steel Austenitic Steel

Nominal Pipe Size (inches) Nominal Diameter DN

Ferritic Steel Ferritic Steel

Nominal Pipe Size (inches) Nominal Diameter DN

Figure 3: Criteria for simplified or computational pipe stress analysis depending on diameter and
temperature

The range where no flexibility check is necessary is based on sample calculations with nomograph for lines with
ratio of 5:1 (length of expanding pipe leg to length of compensating pipe leg).
For ratios higher than that, or a unreinforced tee in the compensating pipe leg (high stress intensification factor) a
suitable check has to be done
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For all piping under the following conditions a computational stress analysis has to be performed
(additionally to the requirements of the diagrams in Figure 3):
Note:
If a computational pipe stress analysis is not performed in one of the following cases, the reasons have to be
documented.
1. Piping connected to equipment and buildings with different soil settlement rates (e.g. tankfarms, wetlands,
loose ground), when one of the following conditions occurs :

settlement Nominal diameter

> 60 mm (2.4") DN 50 (2”)
> 40 mm (1.6") DN 100 (4“)
> 25 mm (1") DN 200 (8“)
> 15 mm (0.6") DN > 300 (12“)
2. Piping connected to rotating equipment (e.g. pumps, compressors, turbines)
Exceptions:
a. Pumps which are not fixed to the foundation
A pipe stress calculation is not necessary when pumps are not fixed to the foundations (only centrifugal
Pumps with horizontal suction nozzle, vertical discharge nozzle and max 40kW driving power). In these
cases the stress engineer has to consider locating an anchorpoint on the suction piping to minimize the
nozzle loads of the pump. The discharge pipeline must be flexible, i.e. the compensating length must be
significant longer (30 – 50%) than required by the simplified method.
As an alternative the stress calculation is not necessary when pumps are not fixed, nominal diameter of
the suction line ≤ DN 50 (2"), maximum allowed temperature ≤ 60°C (140°F) and suction- and discharge-
line have anchors nearby (distance max. 300 mm (12")) the nozzles of the pump.
b. Pumps which are fixed to the foundation
The Stress calculation is not necessary when pumps are fixed and have a nominal diameter of the
suction-line <= 50 (2”) and a max. allowed temperature of ≤ 60°C (140°F). The nozzle loads due to the
weight of the discharge line (including valves, contents, and insulation) must be minimized.
3. Piping connected to equipments with low allowable nozzle loads (for example plate-type heat exchangers,
graphite heat exchangers, glas-lined vessels, air cooled heat exchanger, vessels made of glasfiber reinforced
plastics etc.)
If at first there are no allowable loads available from the vendor the following values can be assumed as
allowable:
plate-type heat exchanger Steel: API STD 662 Part 1Table 2 or DIN EN ISO 15547-1 Table 2
Aluminum: API STD 662 Part 2Table 1 or DIN EN ISO 15547-2
air-cooled heat exchanger API STD 661 Table 4
compressors API STD 617 resp. API STD 619
steam turbines NEMA SM 23
pumps (Europe) EN 5199
pumps acc API API STD 610
For pumps single values are allowed to be higher than given in EN 5199 or API STD 610 when additional
requirements are met.
It has to be checked afterwards whether these values are acceptable or not.
4. Piping with a nominal pressure > 160 bar (2500psi), which require a simplified flexibility analysis according to
the diagrams of page 4.
► Applicable for U.S.: Additional requirements ASME B31.3 Section K ◄
5. Piping with cyclic (pressure and temperature) conditions over 7000 (for lines connected to vessels acc. to
AD 2000: 1000, vessels acc. to EN 13445: neq ≤ 500) cycles throughout the life of the installation.
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6. Jacketed pipes with a diameter of the inner pipe ≥ DN 80 (3”)

7. Piping made of special materials and non-metallic materials, when calculations are required based on the
analyst’s review. Note that a detailed analysis of high alloy material piping systems can result in potential cost
savings from reduced number of expansion loops. For plastic piping extent and method of analysis which will
be used must be decided by the Stress engineer and the Piping Lead Engineer of BASF
►Applicable to Europe: E-P-PI 003 Section 5◄
8. Piping which is critical as designated by BASF regarding 1)
a. hazardous/lethal services
b. critical impact on Plant availability
9. Piping at safety valves or rupture disks. Note that detailed analysis is only necessary when:
- significant cooling or heating of the off line occurs during the relieving event (see diagrams Figure 3),
or
- a high impulse (reactive force) results from a relieving event and the routing of the pipe is too complex to
do a simplified calculation
10. Piping subjected to high wind loadings (wind load > 1500N/m2, local codes must be regarded). If for other
reasons a Pipe stress analysis is performed wind has to be considered.
11. Piping subjected to high loads created by water-hammer, two-phase flow, flashing, abrupt interruption of flow,
or other hydraulic transients.
12. Piping with DN >250 (10”) and liquid media in areas with danger of earthquake (Check local Codes)

► Applicable to for Ludwigshafen.: A computational flexibility and stress analysis is only required for DN >
500. If for other reasons a Pipe stress analysis is performed earthquake
has to be considered.◄
13. Piping connected to pressure vessels which are designed according to AD 2000 or EN 13445:
The inside diameter of the nozzle exceeds 0.3 times the inside diameter of the vessel

1) project specific requirement

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4 Details of calculation and documentation

4.1 General
Pipes, fittings, and other components shall be designed in accordance with the generally acknowledged rules of
technology (e.g. ASME B31.3 resp. ASME B31.1, EN 13480 or AD 2000), to withstand the internal or external
pressure and additional loadings induced from live/dead loads, support/anchorage movement, cyclic effects, wind
load, earthquake and vibration loadings. The applicable loadings have to be combined to form load cases which
take into account the applicable combinations of the imposed loads. The maximum stresses from these combined
load cases have to be below the allowable stresses in accordance with the specific design codes/rules. If the
allowable stresses for an element and a given load case are exceeded, the Stress Engineer and Piping engineer
must make adjustments to routing, supports, etc to ensure compliance.

4.2 Computational flexibility and stress analysis

The stress engineer should attempt to optimize the piping system design so that pipe stresses and equipment
loadings are within allowable, leakage is prevented due to imposed loadings at joints and costs for piping material
and construction are minimized. The computational pipe stress analysis calculations shall be performed according
to ASME B31.3 resp. ASME B31.1 or EN 13480 with the program Caesar II. Other programs have to be accepted
by BASF Stress engineer for every project.

4.2.1 Load cases

• The conditions for the stress analysis will be derived from the line list and may require multiple analyses. The
stress analysis conditions will be the most severe combination of pipe metal temperature and pressure based
on the values shown for start-up, normal operation, upset condition, steam out and shutdown. Additional
conditions may be required and will consider climate effects (for example snow loads, heating by sun etc.)
where applicable.
• Occasional Loads - The effect of wind loading shall be taken into account in the analysis of exposed piping, in
accordance with the requirements of local conditions and standards.
• The stress analysis shall consider horizontal forces due to earthquake according to local conditions and
standards.

4.2.2 Calculation details

• Equipment or machines connected to the lines should be modeled with the calculation program to get correct
stiffness and displacements. When equipment is supported on bracket supports or support legs they must be
modeled to get correct support loads.
• Friction Effects
Friction effects shall be considered for the restraint imposed on the piping system. It is recommended to
consider friction effects when the friction forces can be higher than 2000 N (450 lbs-force) for its effect on the
support structure.
• Vibration
If problems with vibrations have to be considered on basis of experiences with existing plants, supports on
lines connecting to reciprocating pumps/compressors shall be arranged so that the natural frequency of the
piping system does not respond to the forcing frequency of the equipment under all modes of operation up to
and including the fourth harmonic.
• Expansion joints must be adequately supported (up- and/or downstream). The calculation engineer or the
piping engineer shall verify the settings of control and limit rods.
• Cold Spring
The use of cold spring for piping is allowed per Code ASME B31.3 rules (section 319.2.4) resp. EN 13480-3
(section 12.2.6) but shall be limited in use and only applied after a thorough engineering analysis has been
performed, taking into consideration construction and installation tolerances. Due to realistic fabrication
practices a minimum cold spring of 5 mm (0.2”) shall be specified. Proper analysis of cold spring is critical at
load sensitive equipment and requires BASF approval.
• Spring Cans / Hangers
Use of spring cans/hangers is discouraged. Spring cans / hangers should only be used, when the piping
system needs more flexibility than can be achieved by incorporating other means. Sizing shall be evaluated in
the hot and cold load. Separate calculations for liquid and gaseous media have to be performed if applicable.
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4.2.3 Documentation
For a detailed flexibility and stress analysis the following documentation must be provided as paper
documentation and pdf-document on CD:
• Summary Page stating that the pipe, the pumps, the vessels, etc. passed the required analysis.
• Any modifications required to ensure Code compliance
• Electronic copies of stress analysis runs converted to Word format
• The following reports have to be included in the documentation:
- Input listing
- Plot of piping (Caesar II)
- Isometric of piping with calculation nodes
- Operating displacements
- Restraint summary
- Stress reports (Operating, Sustained and Expansion modes)
- Occasional load conditions and stress report, if applicable
- Details of special supports and their calculations if applicable
- Hanger tables, as applicable
- Technical data sheet of expansion joints, if applicable
- Sketches or drawings of connected equipment with calculation nodes
- Rotating equipment load summations, showing that loads meet the applicable criteria (eg Manufacturers
allowables, API or NEMA requirements)
- WRC 107, WRC 297, finite elements calculations or other detailed calculations of connected nozzles,
showing the summation of stresses, loading type) eg. operating, expansion, or sustained) and allowable
stress used, as applicable. The computer program used for finite element analysis for fixed equipment
nozzle load evaluation should be FE-Pipe and/or Nozzle Pro unless stipulated otherwise by BASF.
- Calculations showing relief or vent valve reaction forces, as applicable
• Disk copy of the Caesar II computer files and nozzle calculations if applicable

4.3 Simplified method

The stresses from gravitational forces and temperature fluctuations can be determined using a simplified analysis
in accordance with ASME B31.3 section 319.4.2 a) and b), EN 13480 section 12.2.10.2 or
AD 2000-Merkblatt HP 100 R section 6.2. The calculation details of the simplified method are described in App. 1
of this procedure. Using the simplified method the stresses due to internal pressure, forces of gravity and
deflections are limited to low values so that is possible to treat internal pressure, weight and thermal expansion
separately.
The following points apply to piping which is not buried. For buried piping, additional considerations (for example
earth loads, restricted expansion in the earth, restraint of momentum, or undermining) are to be specified to suit the
particular case.
The simplified check of flexibility and maximum piping spans has to be performed with the Excel sheet “G-P-PI 270,
Pipe Stress Analysis: Simplified Method BASF”.
The Excelsheet "G P PI 270.xls" is available at GTE/BE (mail: rolf.limpert@basf.com) and can be used by all
trained persons (BASF and for BASF working engineering companies).
Alternative methods using industry standard graphical solutions, or other published methods, may be used for the
simplified analysis at the discretion of the piping stress analyst. These methods must ensure that both primary and
secondary stresses are within the allowable values.
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4.3.1 Maximum Piping Spans

The maximum allowable spacing of supports for steel pipes (such as carbon or austenitic steels) is given in Table
1a – 1f of Annex 1. The explanatory notes regarding these distances must be followed. For other materials or
higher temperatures, Tables 1a – 1f in Annex 1 can be converted in accordance with the notes.

4.3.2 Flexibility Check

To ensure adequate flexibility (e.g. thermal expansion of the piping and induced loads), a piping system shall
adequately allow for bending or torsional deformation. This is normally achieved by suitable routing.
Displacements of connected equipments or piping and thermal expansion restricted by supports or guides must be
included into the calculation. For 3-dimensional piping or several piping in different directions connected to each
other, a check of every part is necessary (in several directions if applicable).
Long piping runs in rack areas have to be checked whether large displacements due to thermal expansion may
cause interferences with adjacent lines.

4.3.3 Documentation
For simplified calculations acc to Annex 1, the calculation documentation should, as a minimum, include:
• Excel sheet showing line characteristics such as size, material, temperature, pressure, allowable stress, flange
ratings, P&ID no. calculation details and results and checked sector of piping
• Isometric sketch of the line with information concerning pipe class, displacements of supports or connected
equipment if applicable
• Other comments as applicable
Explanatory notes concerning formula and theory and examples of application of the simplified method are given in
Annex 1 of this procedure.
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5 References
The DIN EN standards cited in the text are identical with the EN standards bearing the same numbers.
AD 2000-Merkblatt Bauvorschriften
AD 2000-Merkblatt HP 100 R Bauvorschriften - Rohrleitungen aus metallischen Werkstoffen
API STD 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries
API STD 617 Axial and Centrifugal Compressors and Expander-compressors for Petroleum,
Chemical and Gas Industry Services
API STD 619 Rotary-Type Positive-Displacement Compressors for Petroleum, Petrochemical and
Natural Gas Industries
API STD 661 Air-Cooled Heat Exchangers for General Refinery Service
API STD 662 PART 1 Plate Heat Exchangers for General Refinery Services - Part 1 - Plate-and-Frame
Heat Exchangers
API STD 662 PART 2 Plate Heat Exchangers for General Refinery Services - Part 2 - Brazed Aluminum
Plate-fin Heat Exchangers
ASME B31.1 Power Piping
ASME B31.3 Process Piping
DIN EN 13445 Unfired pressure vessels; German version EN 13445
DIN EN 13480 Metallic industrial piping; German version EN 13480
DIN EN 13480-3 Metallic industrial piping - Part 3: Design and calculation; German version EN
13480-3
DIN EN ISO 15547-1 Petroleum, petrochemical and natural gas industries - Plate-type heat exchangers -
Part 1: Plate-and-frame heat exchangers; English version EN ISO 15547-1
DIN EN ISO 15547-2 Petroleum, petrochemical and natural gas industries - Plate-type heat exchangers -
Part 2: Brazed aluminium plate-fin heat exchangers;
English version EN ISO 15547-2
DIN EN ISO 5199 Technical specifications for centrifugal pumps - Class II;
German version EN ISO 5199
E-P-PI 003 Fachplanung Rohrleitungstechnik
NEMA SM 23 Steam Turbines for Mechanical Drive Service

6 Annex
Issue
Annex 1 Span tables, formulas, explanatory notes and application examples Sep 2011