HAR-WI-EN-PI-003

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WORK INSTRUCTION
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PIPE STRESS ANALYSIS

WORK INSTRUCTION

Revision 0
Prepared by: V. Patel
Checked by: ME/Piping CoP
Approved by: J. Uptigrove
Date Issued: 04.19.2022
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TABLE OF CONTENTS

1.0 PURPOSE ...................................................................................................................................................................3

2.0 APPLICABILITY .....................................................................................................................................................3

3.0 REFERENCES ...........................................................................................................................................................3

4.0 DEFINITIONS ..........................................................................................................................................................3

5.0 RESPONSIBILITIES ..............................................................................................................................................4

6.0 PIPE STRESS ANALYSIS ...................................................................................................................................5

7.0 STRESS ANALYSIS WORKFLOW...............................................................................................................6

8.0 ENGINEERING AND ANALYSIS ............................................................................................................... 14

9.0 EQUIPMENT NOZZLE LOADS .................................................................................................................. 21

10.0 SUPPORT DESIGN ............................................................................................................................................ 22

11.0 DOCUMENTATION ......................................................................................................................................... 24

12.0 DELIVERABLES ................................................................................................................................................... 25

13.0 APPENDIX A: COMBINATION OF LOAD CASES IN CAESAR-II ........................................ 28

14.0 APPENDIX B: PIPE SPAN CHART.......................................................................................................... 31

15.0 APPENDIX C: PIPE GUIDE SPACING CHART................................................................................ 35

16.0 APPENDIX D: STRESS ANALYSIS WORKFLOW.......................................................................... 36

17.0 APPENDIX E: FOLDER STRUCTURE ................................................................................................... 37

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1.0 PURPOSE
The intent of this document is to standardize the procedures, responsibilities, and guidelines for
stress analyzing piping systems to meet all applicable industry codes and safety requirements.
Additional requirements may be added to meet Client or project specific requirements (unique
facilities, equipment, or industries) which should be documented in the Project Execution Plan and
communicated to the project team. Deviation from the requirements documented herein shall
require prior approval from the Discipline lead & Piping Engineer of Record (EoR).

2.0 APPLICABILITY
This document will be used in conjunction with HAR-PRO-EN-PI-003 to perform pipe stress
analysis work. Pipe stress specification or work instruction from the client takes precedence over
Hargrove pipe stress specification.

3.0 REFERENCES
3.1. PIP PNC00004 Piping Stress Analysis Criteria for ASME B31.3 Metallic Piping
3.2. HAR-PRO-EN-PI-003 Pipe Stress Analysis Procedure
3.3. HAR-TP-EN-PI-001 Piping Loads on Equipment Nozzles
3.4. HAR-EST-EN-PI-001 Pipe Engineering MH Estimating Tool
3.5. HAR-CKL-EN-PI-001 Pipe Stress Checklist
3.6. HAR-FM-EN-PI-001 PSV Reaction force calculator
3.7. HAR-TBL-EN-PI-001 SIF Table
3.8. HAR-TBL-EN-PI-002 Pipe Support Span Table
3.9. HAR-RPT-EN-PI-001 Pipe stress progress tracking tool
3.10. HAR-XXXXXX-PI-LST-101 Engineered support list
3.11. HAR-XXXXXX-PI-DB-001 Project specific Pipe stress design basis
3.12. HAR-XXXXXX-PI-CAL-001 Stress report cover sheet template
3.13. HAR-XXXXXX-PI-FM-101 Static Equipment Nozzle load form
3.14. HAR-XXXXXX-PI-FM-201 Rotating Equipment Nozzle load form

4.0 DEFINITIONS
PIP – Process Industry Practice
DL – Discipline Lead
EoR – Engineer of Record
PSA – Pipe Stress Analysis
SIF – Stress Intension Factor
PTT – Project Tracking Tool
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DTT – Discipline Tracking Tool

SDC – Single Discipline Check
IDC – Inter Discipline Check

5.0 RESPONSIBILITIES
Stress Discipline Lead can delegate some of the responsibility to pipe stress engineers as needed.
Description Tool / Document Responsibility
Estimating the stress engineering budget required Refer Pipe Stress
for the project based on the criticality of lines, HAR-EST-EN-PI-001 Resource leader
number of lines and systems to be analyzed and or Discipline Lead
the type of analysis required, i.e., visual, or formal
calculations.
Development & maintenance of a stress isometric Refer Discipline Lead –
tracking chart for monitoring progress of each line HAR-RPT-EN-PI-001 Pipe Stress
requiring stress analysis.

Monitoring the schedule and budget for the stress PTT / DTT / PTDB / Discipline Lead –
work required for the project. Schedule Pipe Stress
Review and sealing of all piping isometrics and/or EoR – Piping
stress reports (if required). Engineer of
Record
Preparation of Stress Critical Line List according to Line list with design Discipline Lead –
HAR-PRO-EN-PI-003 conditions, P&ID and Pipe Stress
HAR-PRO-EN-PI-003
Create project specific pipe stress design basis HAR-XXXXXX-PI- Discipline Lead –
DB-001 Pipe Stress
Discipline lead of pipe stress and pipe design and Line list, P&ID and Discipline leads,
Project engineer together decide on priority of schedule Project Engineer
stress calculations
Generation of stress isometrics per stress critical Stress Critical line list Piping Designers
line list priority
Perform Pipe stress analysis as per Work CAESAR-II, Piping Stress
instruction HAR-PRO-EN-PI-002 NozzlePro, FEATools Engineer
Co-ordinate to optimise the routing & supports Piping Stress
with the Piping Designer & ensure the safety of the Engineer
piping & equipment
Co-ordinate with other departments i.e., Civil and Piping Stress
Equipment for special requirements Engineer
Documentation of the System as per the Para 7 Bluebeam Revu Piping Stress
and 8 of the work instructions stress markup tool Engineer
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Checking of the results by analyst and qualified Hargrove Checklist Qualified Checker
checker as per the check list HAR-CKL-EN-PI-001 assigned by
Resource Leader
Final Approval of stress analysis calculations Single discipline EoR and Resource
checking report lead
(HAR-RPT-EN-QA-
001)
Preparation and Issue of the Engineered Support AutoCAD Piping Stress
Drawings Engineer
Incorporate comments/changes given by stress Piping Designer /
group Checker

All non-critical lines (Category NR) shall be Piping Designer /

adequately supported Checker

To review final isometrics and to ensure all Piping Designer /

comments/changes/recommendations for critical Checker /
lines given by stress group are taken care in model Engineer of
before drawings are issued for construction. Record (EoR)

6.0 PIPE STRESS ANALYSIS

Pipe Stress Analysis shall be performed in accordance with the piping code defined in the project
pipe stress design basis. Piping flexibility must comply with ASME B 31.3 unless stated otherwise.
In general, piping systems shall have sufficient flexibility to prevent thermal expansion or contraction
or movements of piping supports and terminals from causing:
a. Failure of piping or supports from overstress or fatigue
b. Leakage at joints
c. Detrimental stresses or distortion in piping and valves or in connected equipment
(i.e., pumps and turbines,), resulting from excessive thrusts and moments in the
piping
When performing pipe stress analysis, the following shall be considered:
a. Stresses in piping system must be within the allowable limits of applicable code
b. Loads and Moments on equipment nozzles should be within allowable limits of
applicable standards or specification
c. To Determine type of supports and their locations keeping displacements and loads
on support within allowable limits of applicable standards or specifications
d. To Prevent excessive pipe sagging between two adjacent pipe supports
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e. To Avoid unintentional disengagement of piping from its supports

f. To Determine type, location, displacements, rotations, and stiffness of expansion
joints
g. To Determine type, location, displacements, loadings and installation conditions of
spring hangers and spring supports
h. To Provide recommendations to piping design for economic piping layout and
support concept
i. To Avoid resonance due to imposed vibration or fluid induced vibration
j. To Design special supports requiring complex design details or impractical
construction tolerances

7.0 STRESS ANALYSIS WORKFLOW

Refer Appendix D for pipe stress analysis workflow chart.
7.1 Selection of Stress Critical Lines
Selection of Stress Critical Lines shall be based on below criteria:
a. Pipe size
b. Design temperature
c. Design pressure
d. Connected equipment
e. Fluid service, fluid category and hazard degree
f. Occasional loading conditions (wind, earthquake, snow)
g. Project specific requirements
h. Special conditions and loads (i.e., transport, explosion, cyclic service)
The Discipline lead for pipe stress, in cooperation with the Piping design team leader is
responsible for the identifying scope of stress analysis. All piping systems to be analyzed by
stress group will be either marked up in the P&ID or critical lines to be identified in Line list
as described below in accordance with selection criteria specified in HAR-PRO-EN-PI-003:
a. Comprehensive Analysis (Category C)
Comprehensive Analysis: Piping in this category requires a comprehensive
analysis (typically by computer). Other methods may be used with owner’s
approval. Documentation is required.
Lines falling in this category as specified in Figure 1 and 2 of PIP PNC00004
are to be brought specifically to the attention of the lead engineer and EoR,
and the level of investigation shall be established on an individual case basis.
Review of these lines to be carried out very early in the Project. Some of
the lines from section 3.4.1 of PIP PNC00004 may fall into this category as
defined in clarification section 8 under 3.4.1 of HAR-PRO-EN-PI-003.
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b. Formal Analysis (Category F)

Formal Analysis: Piping in this category requires formal analysis. Analysis
may be performed by approximate, comprehensive, or computer methods.
Documentation is required. Some of the lines from section 3.4.1 of PIP
PNC00004 may fall into this category as defined in clarification section 8
under 3.4.1 of HAR-PRO-EN-PI-003
All lines which fall into formal category shall be investigated by approximate
methods primarily. Only in below special cases computer stress analysis
shall be performed.
i. Piping of equipment which is directly connected to each other (e.g., re
boiler or condenser directly Connected to column) regardless of the
design temperature
ii. Other exceptional lines based on Project requirement
Approximate methods may be applied to meet the relevant code
requirements and to ensure adequate support spacing and sufficient
piping flexibility. A formal documentation of approximate methods is
not needed.
If approximate methods are not applicable due to the complexity of
piping systems, or application of these methods leads to excessive
loops, a computer stress analysis shall be performed.
Economic aspects and special requirements of the plant type shall be
considered in deciding whether a computer stress analysis is required
or not.
Normally, the consequent application of approximate methods is very
conservative so that in case of large piping an exact calculation by
computer analysis often leads to a more economical solution.
Visual Analysis (Category VIS)
Visual Analysis: Piping in this category may be analyzed using engineering
experience or approximate methods. Stress markup isometrics are required
as minimum documentation requirement.
Lines falling in Category C and F can be classified as Category VIS lines in
specific cases when below conditions are met.
i. Piping systems which are duplicates or replacement without significant
change of existing piping or a system operating with a successful service
record
ii. Piping systems which can readily be judged adequate by comparison
with previously analyzed systems.
Small bore piping with NPS 3 or smaller and Piping with low
temperature ranges may be checked by visual inspection.
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c. Analysis Not Required (Category NR)

Piping in this category is typically noncritical lines which are reviewed by the
Piping Designer / Piping Design Checker using best industry practices and
design experience. EoR approval is required to use Category N designation.
7.2 Input to Stress Group
Discipline Leads of Pipe stress, Pipe design and Project engineer together decide on priority
of stress calculations.
Piping Design should include the following with the piping stress isometric to accurately
analyze the system:
a. All isometrics belonging to stress package as identified in line list or on
P&ID
b. PCF files for respective isometrics
c. All pipe supports shown on the isometric
d. Any continuation isometrics
e. Any pertinent existing drawings
f. Existing support locations at tie-ins. At least several existing supports past
the tie-in will be required preferably to an anchor point in each direction
g. All Isometrics to be analyzed shall be reviewed by the Piping design team
leader before they are handed over to the stress group, incomplete stress
isometrics / stress package shall be returned to piping design
Process group
a. Provides design data such as temperature, pressure, fluid density, fluid
category, insulation type and thickness in line list
b. Process group provides information about lines or equipment subject to
cool down / upset condition, start up, shut down or steam out conditions
c. Process group shall identify which lines are subjected to slug flow, two
phase flow, acoustic or flow induced vibration and subject to severe cyclic
condition (more than 7000 cycles) in plant life on the process line list
Mechanical group provides equipment design information such as mechanical data sheets,
vendor drawings, allowable nozzle loads.
Instrumentation group provides instrument weights and installation requirements
Material information is obtained from respective pipe class
7.3 Project specific set up and work assignment
The project specific “caesar.cfg” and “unit” files are prepared by discipline lead and saved in
project folder
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Discipline lead creates project specific Design basis document as per template HAR-
XXXXXX-PI-DB-001.
Based on priority of stress calculations and availability of stress isometrics, discipline lead
assigns the stress calculation to team
Discipline lead keeps track of project progress, budget, PCN, schedule. Progress report
template is available in CoP page, HAR-RPT-EN-PI-001
7.4 Modeling guidelines
7.4.1 General
Stress analyst shall copy caesar.cfg” and “unit” files in CII folder from project folder
before starting modeling
Global co-ordinates shall be defined at start node as given in isometric, adjust
elevation as required with respect to grade level
Valve, flange, and other pipe component weights are taken from CAESAR-II
database. The weights of control valves are considered from past project data or
1.5times the weight of Gate valve whichever is higher in absence of current design
data
Elbow with immediate flange modelled as elbow with one flange/ double flange
option
Any queries related to process to prepare different operating cases are discussed
with process department
At control valve stations axial stop or an anchor on one side of the control valve is
preferred to avoid vibration
Use of special supports, springs and expansion joints shall be avoided or to be kept
minimum
In steam system, bypass lines and other non-operating lines are considered at the
saturation temperature of steam
For steam traced lines, whichever is greater of the design temperature of the traced
line or 70% of the steam temperature shall be used.
Battery limits / Tie-ins
a. Piping shall be anchored at the process plant plot limit, battery limits, or
interface limits between other contractors (coordination with the
contractor should be undertaken in the beginning of the project to
determine which side of the piping the anchor is to be located). Exceptions
may be made with Client’s approval.
b. When tying into existing piping, the analysis shall include enough existing
piping and pipe supports to define the boundary conditions (to the nearest
anchor point or logical discontinuity when anchors are not available) and
accurately evaluate the tie-in.
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Branch Connections
a. When a branch type is selected in Caesar II, code generated SIFs are
automatically inserted (ASME B31J).
b. FEA can be used to calculate more accurate SIF’s. FEA generated
flexibilities or the Caesar II Class I Flexibilities can also be used in-order to
develop more realistic stresses at the branch connections.
c. For large headers, the off-set command, or a weightless rigid from the
center of the header to the outside edge of the header should be
considered.
7.4.2 Modeling Equipment in Caesar II:
Vessels
a. Model the piping through the vessel nozzle with a c-noded anchor at the
intersection of the nozzle with the vessel wall (add c-node anchor at the
nozzle flange face if needed).
b. Use the diameter of the vessel as the diameter of the rigid member from
the vessel wall to the vessel centerline.
c. If needed to reduce nozzle loads, add inherent flexibilities at the vessel
interface by modeling the nozzle in Caesar II utilizing the built-in WRC-297
nozzle builder or by using a flexible nozzle which requires inputting
stiffness’s generated by FEA (NozzlePro) at the vessel interface. For tall
columns, startup and shut down cases shall be considered
i. Startup Condition
Regarding the analysis of vapor line from the top of a tower,
calculation shall be conducted on the assumption that the
vapor piping is at 50% of temperature while the tower is at
its ambient temperature
ii. Shut Down Condition
Regarding the analysis of vapor line from the top of a tower,
calculation shall be conducted on the assumption that the
vapor piping is at ambient temperature while the tower is at
50% of design temperature.
Pumps & Compressors
a. Model the suction and discharge piping to/from the center of the pump
casing or up to anchor point in ANSI pumps. Model the pump elements as
rigid and add a C-Node at the pump nozzle to obtain flange loadings to
compare to allowable. For pumps where the allowable loads resolve to the
center, model both the suction and the discharge piping in the same model.
b. Displacement shall be checked by freeing nozzle flange to ensure alignment;
it should be less than 0.1” in any direction
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c. When modeling multiple pump arrangements, set the temperature break

point for the cold pump at the upstream side of the primary block valve for
the suction and on the downstream side of the primary block valve for the
discharge.
d. For more than two pumps, different combinations of temperature cases
shall be prepared considering stand by case
• For example, in the case of stand-by pumps, when the pump is
equipped with a by-pass on the check/ shut-off valve assembly, a
temperature corresponding to 70% of the operating temperature
shall be assumed for the stand-by line.
• In case of no warm-up by-pass, the temperature for the lines of
non-operating equipment shall be assumed as follows:
o Average of ambient and operating temperature for
insulated lines (TS)
o 25% of the delta between operating and ambient
temperature should be added to ambient temperature
for non-insulated lines (TS)
However, the calculation shall be carried out for any possible configuration
of spare operating machine. For lines at rotating equipment with a standby
equipment the following cases must be considered. An example with one
spare pump is shown below:

TS
TS

A B

Operation Spare

Pump A Pump B
a) on off
b) off on
c) on on
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e. Regarding centrifugal compressors, there are cases where the air operating
temperature becomes higher than the normal operating temperature.
Calculations shall be conducted for the higher of the two temperatures
f. Bypass Operating Conditions: Basically, bypasses shall be considered as out
of operation in at least some operating cases. In these cases, the bypass lines
have either ambient temperature or (in case of steam or steam condensate)
saturated steam temperature.
Heat Exchangers
If modeling shell and tube exchanger as pipe, extra thick shell walls (5X) can be used
for modeling purposes to simulate the additional stiffness’s associated with the
inside tubes.
Air Cooled Heat Exchanger
The thermal growth of the tube bundles and header boxes shall be carefully studied
together with the type and layout of the air-fin cooler. Stress requirements for the
supports, sliding plates and header box and frame clearances shall be coordinated
with the Mechanical/Equipment Group and the Vendor during the development of
its final drawings. Listed below are some of the items the stress analyst should take
into consideration:
a. For Single Pass air-fin coolers, the inlet header box shall be directionally
fixed and the outlet box free to slide to allow for tube expansion. The inlet
and outlet header boxes shall follow the thermal growth of their respective
pipe headers.
b. For Double Pass air-fin coolers, the inlet and outlet are at the same end and
shall be directionally fixed. The header box shall follow the thermal growth
of the inlet pipe header and the flexibility of the outlet piping shall be
designed to accommodate for the differential expansion between the inlet
and outlet.
c. Multiple header boxes or bays connected by a common pipe header shall be
designed to move laterally within their supporting frame to allow for the
pipe header expansion. If necessary, thrust blocks may be inserted between
header boxes to assist in the movement of multiple bays. Clearance
requirements within the frame and the thrust blocks shall be coordinated
and agreed upon with the Vendor.
Storage Tanks
The tank settlement, stiffness of the tank shell, radial deflection, and meridional
rotation of the nozzle at the shell connection resulting from fluid head, pressure,
and uniform or differential temperature between the shell and bottom shall be
considered in the analysis. The built-in feature of Caesar II can calculate for the
stiffness and effects of bulging based on the API 650 standards.
Jacketed Piping
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Modeling of jackets piping should be as per below guidelines:

a. Code core piping providing nodes for spiders and at same location on
jacket, etc.
b. Copy core piping & increment for jacket
c. Change diameter for jacket pipe
d. Change jacket elbows to short radius
e. Connect core and jacket together at flanges with anchor and connect point.
f. Place spiders as required as lateral stops only. (i.e., X & Z for vertical pipe).
Do not gap these stops. C-node restraints to jacket.
g. Specify specific gravity of jacket fluid. Deduct for core pipe.
h. Apply supports to jacket
i. Apply insulation to jacket
j. Remove the jacket pipe for rigid components that are not jacketed.
k. Correct the reducer input for each one the jacket. Changing the diameter
on the listing does not correct the reducer input.
Support Modeling in Caesar II
Trunnion
a. Pipe trunnions should be modeled in Caesar II as pipe and not as rigid. For
large headers, the off-set command, or a weightless rigid from the center of
the header to the outside edge of the header should be used.
b. First 4” of trunnion length near connection shall be modeled at operating
temperature and rest of the length shall be modeled at ambient
temperature.
c. Define un-reinforced branch connection at trunnion – bend connection. If
overstresses warrants more accurate SIF, then FEA calculated SIF’s (Stress
Intensification Factors) can be manually inserted into Caesar II (refer HAR-
TBL-EN-PI-001). To ensure Caesar II orientates the in plane & out plane
SIF’s properly the higher of the two SIF’s can be applied to both in plane &
out plane (required method for B31.1).
Springs
a. Spring cans shall be modeled with friction where horizontal movement is
greater than 1/2” or near load sensitive equipment nozzle.
b. When pipe thermal movement is greater than 1/2” on F-type spring cans,
low friction slide plates shall be used to avoid imposing bending on the
spring column.
c. When spring supports are used on liquid lines of 24” and larger the Stress
Engineer shall consider a load case with the spring active but with no
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content (WNC). Particularly for piping with spring supports connected to

large tanks (API 650 Tanks) that might be empty in case of draining, causing
excessive upward force on piping and tank nozzle.
Structural Steel
Structural stiffness values should be considered for critical supports, supports with
large loads or supports have horizontal loads, particularly T-poles and bents.
Structures can be modeled in Caesar II utilizing the structural modeler or by
manually entering a stiffness value for the restraint. Loads should be reported back
to the structural department.

8.0 ENGINEERING AND ANALYSIS

Thermal stresses and support type selection of piping systems must be complied with ASME code
and relevant project specifications.
For cases not covered by above codes and standards, specific solutions shall be adopted according
to experience and good design practice.
8.1 Loads to be considered
8.1.1 Sustained Loading
Dead Weight
For determination of dead weight or operating weight of a pipe system the following
shall be considered:
a. Pipe weight
b. Fluid weight
c. Insulation, Refractory, or lining weight
d. Weight of flanges
e. Valves, other inline piping components and actuators
Additionally, the weight with no contents (WNC) or empty weight shall be
considered for springs when spring is located near equipment nozzle to check
nozzle loading in sustained condition.
Pressure Loading
The pressure for the pipe stress calculation shall be the design pressure as stated on
the line list. For piping systems with expansion joints additional considerations with
operating pressures and hydro pressures may be required.
8.1.2 Thermal Loading
For temperature and thermal expansion, the following shall be considered:
a. The flexibility analysis for each stress range to be evaluated for each
anticipated operating condition shall be based on the maximum operating
temperature for that condition unless calculations are supplied to and
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approved by the owner that better predict the pipe metal temperature for
the condition.
b. The upper design temperature according to line list shall be used for the
determination of the allowable hot stress.
c. Calculation of expansion stresses shall be based on the difference between
the lower and upper design temperature.
d. For piping systems with thermal cycles that exceed 7000, the calculated
flexibility stress (Se) shall be evaluated according to ASME B 31.3
e. Reactions on supports, nozzle loads on connected equipment, and
displacements by thermal expansion of piping shall primarily be calculated
for the operating temperature.
f. If technically and economically justified, relevant maximum operating
temperatures may be used for the calculation of nozzle loads, reactions on
supports, displacements and expansion stresses for hot lines and minimum
design temperature for cold lines. Operating temperatures shall be taken
from process data sheets, technical specifications, line lists, or they are
provided by licensor. Safety aspects shall be considered.
g. All relevant operating temperature combinations, hot-cold system
combinations, stand-by combinations shall be considered if they are
regarded as critical.
h. Climatic effects shall be considered in determining the maximum differential
temperature.
In cases of extreme climate conditions, the installation temperature should be
assumed as follows:
Note: If climate conditions and different design temperatures require that different
installation temperatures shall be used then separate CAESAR runs shall be
performed. CAESAR II uses the term ambient temperature for installation
temperature. However, the specified minimum and maximum ambient temperature
need not be used for the pipe stress analysis itself.
Table 2: Determination of installation temperature
Climate conditions Installation temperature
Minimum ambient Maximum ambient
Climate type For hot piping For cold piping
temperature temperature
Moderate Not below -4 °F Not over +104 °F +70 °F +70 °F
Cold Below -4 °F Not over +104 °F +15 °F +70 °F
Hot Not below -4 °F Over +104 °F +70 °F +85 °F
Extreme Below -4 °F Over +104 °F +15 °F +85 °F
i. The metal temperature from the effect of solar radiation in the summer and
the winter dry bulb design temperature should be considered. Any un-
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insulated piping systems that are subjected to solar radiation heat gain shall
use temperature based on plant location.
8.1.3 Friction
The frictional resistance to thermal movement of the pipe shall be considered. The
greater loads of those evaluated with friction and those evaluated without friction
shall be used for reaction loads, flexibility-based stress range analyses, and sustained
load analyses and shall be documented.
Frictionless unrestrained movement of the piping system shall be assumed only if the
entire system is supported by means of rod or spring hangers.
When it is apparent that frictional effect will significantly increase nozzle loadings,
analysis shall include frictional effects. When required, friction co-efficient shall be
considered as defined below.
Surface Friction co-efficient
Rolling Supports 0.05
PTFE to Polished Stainless Steel 0.1
Teflon to Teflon 0.1
Graphite to Graphite 0.15
Steel to Steel 0.3
Steel to Concrete 0.6
8.1.4 Pressure Test Loads
In general, hydrostatic test conditions shall be considered. The test pressure shall be
calculated in accordance with the relevant piping code or may be taken from the
line list.
For pressure test in pipe stress calculation, it shall be assumed that all lines are
insulated, and all springs are blocked.
Temporary supports may be used if the support system is not strong enough to
support the water-filled piping during hydro test and same shall be marked on
isometric. Hydro test loads on springs shall be verified.
According to ASME B 31.3 para 345.4.2, hydrostatic test pressure at every point in
metallic piping shall not be less than 1.5 times the design pressure, and para 345.5.4
limits pneumatic test pressure shall not be less than 1.1 times the design pressure.
8.1.5 Occasional Loading
Occasional loads are generated by such loads as wind, earthquake, steam/water
hammer, and fluid transient forces. The sum of all longitudinal stresses, including
both sustained and occasional loads, are limited to 1.33 times the basic allowable
stress at the maximum operating temperature. Occasional thermal loadings are
excluded.
Wind Loads
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a. The wind loads on piping systems shall be determined in accordance with

the procedure outlined in ASCE 7 or as specified by owner.
b. Detailed wind data shall be provided in the project pipe stress design basis
based on plant location.
c. A wind shape factor of 0.7 for cylindrical vessels and piping shall be included
in wind case analysis unless stated otherwise.
d. The wind load shall be considered for pipes with 12” and larger diameter
including insulation above 30 ft. from grade and when not shielded. (OR
smaller sizes and lower elevation as determined necessary by Engineer of
Record).
e. The effect of shielding by the structure and piping may also be considered at
the discretion of the Engineer of Record.
f. Correct elevation of start point in CAESAR II must be specified to
accurately consider the wind effect.
Seismic Loads
a. If specified by owner or required by jurisdiction, seismic loads on piping
systems shall be considered.
b. Detailed seismic data shall be provided in the project pipe stress design
basis based on plant location.
c. Pipe acceleration due to earthquake shall be considered as a static uniform
load according to the applicable earthquake code and site conditions.
d. Seismic loads shall be included in formal analysis for NPS >= 8 (OR smaller
sizes as determined necessary by Engineer of Record).
e. Vertical seismic vector U2 can be disregarded if it’s value is negligible.
Pressure Safety Valve Reaction Forces
The reaction forces that occur during relieving (blow-off) are considered in the pipe
stress analysis when evaluating occasional loads and stresses.
For all safety relief valves outlet lines an anchor support or axial stop is preferred to
prevent deflection and forces from transferring to equipment or piping causing
overstresses. For two or more parallel safety valves the stress analysis shall consider
the different operating conditions. All reaction forces during blowing off shall be
considered in the analysis. The stresses resulting due to these blowing off conditions
are analyzed as an occasional load case.
In absence of vendor data, maximum reaction force and subsequent reaction forces
at downstream elbows are calculated using HAR-FM-EN-PI-001.
Reaction forces at downstream elbows are based on below method:
𝐿𝐿𝐿𝐿
𝐹𝐹𝐹𝐹 = 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 ( ) ……... (1)
𝑎𝑎∗𝑡𝑡0
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Where,

𝐹𝐹𝐹𝐹 Reaction force at downstream elbow

𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 Stationary maximum reaction force = 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 = 𝑚𝑚𝑚𝑚 + 𝑃𝑃𝑃𝑃
𝐿𝐿𝐿𝐿 Straight length of downstream pipe section
𝑛𝑛 1, 2, 3... Number of downstream pipe section
𝑚𝑚 Mass flow
𝑎𝑎 Sonic velocity at throat = √𝑘𝑘𝑘𝑘𝑘𝑘/𝑀𝑀𝑀𝑀
𝑃𝑃 Pressure
𝐴𝐴 Area

Note: Eq. 1 is referenced from “Piping Stress Engineering” by L.C. Peng, Page-401,
eq 12.54 in book.
Reaction force directions are illustrated in figures below with different blow off
cases.

Case 1: Blow off into atmosphere (horizontal

blow off) Case 2: Blow off into atmosphere (vertical
blow off)
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Case 3: Blow off into atmosphere (horizontal Case 4: Blow off into atmosphere (Blow off
line) line under an angle to the horizontal)

Case 6: Blow off into the flare

Case 5: Blow off into atmosphere (vertical

blow off line with T)

Snow and Ice Loads

Snow and ice loads shall not be considered for all outdoor piping according to
applicable code and site conditions in operating and in shut-down cases (with or
without content).
For operating cases snow or ice loads shall only be considered for:
a. Non-insulated piping with mechanical design temperature ≤ +122°F
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b. Insulated piping with mechanical design temperature ≤ +212°F

Snow or ice loads may be considered as occasional loads. Detailed information shall
l be provided in the project pipe stress design basis.
Water Hammer
Water hammer type events are usually caused by the instantaneous stoppage of a
fluid flow such as the rapid closing of an automated valve. This causes momentary
internally unbalanced forces in the piping as the system seeks to restore equilibrium.
To approximate the force created at each elbow as the pressure wave travels
through the piping system, a static approach can be used:

F = DLF * ∆P * A

DLF = dynamic load factor = 2

A = internal pipe area

∆P = pressure wave = (ρ * c * V) + P

ρ = fluid density

c = pressure wave velocity = speed of sound in the fluid

V = operating flow velocity

P = operating pressure

Vibration
Piping shall be supported and designed to eliminate excessive vibration that is
caused by two phase flows, turbulent flow vortices, wind, acoustically induced, etc.
Guidelines on vibration is given in Energy Institute Guidelines.
Equipment and Support Settlement
Long term settlement of equipment, steel and supports shall be considered based on
the soil conditions and Geotech report.
Load cases shall be modified to include displacement resulting from long term
settlement. Stresses in the piping due to settlement shall be considered primary
stresses (sustained).
Piping connecting to equipment and steel experiencing settlement shall have
adequate flexibility and may require the use of spring cans or expansion joints,
depending on space constraints in the area. If possible, have the pipe support
pedestal extended from the equipment foundation or the pipe support pedestals
resting on the same mat as the equipment.
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Flanges
External bending moments on flanges shall be considered.
External loads may be analyzed by the equivalent pressure method or other
methods approved by owner.
Acceptance criteria shall be in accordance with owner’s requirements.
Special Load Conditions
When requested or relevant, additional load conditions shall be considered for pipe
stress analysis, some examples are:
a. Cool down and upset conditions
b. Startup and shut-down conditions
c. Steam out conditions
d. Blast loads and explosion
e. Acceleration loads
f. Structural deformations
g. Foundation settlements
h. Transportation loads
Detailed information shall be provided in the project pipe stress design basis.
Loads not covered by pipe stress analysis
The Process group shall identify which lines are subjected to slug flow, acoustic or
flow induced vibration and subject to severe cyclic condition (more than 7000
cycles) in plant life on the process line list.
Unless requested by the client, the process OR safety department, the following
loads and conditions need not to be considered by pipe stress analysis:
a. Water hammer
b. Slug flow
c. Pulsation
d. Acoustic or Flow inducted vibration
Load Combination
Load cases are built based on different load combinations (static, wind, seismic and
safety valve popup). (Refer Appendix - A)
For hydrotest and WNC load case hanger stiffness will be considered rigid.

9.0 EQUIPMENT NOZZLE LOADS

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HAR-TP-EN-PI-001 shall be used for allowable equipment nozzle loads. Mechanical engineering
discipline lead along with PE/PM and procurement is responsible to include HAR-TP-EN-PI-001
“Piping loads on Equipment Nozzles” in RFQ package during RFQ process The Stress Engineer is
responsible to apply allowable nozzle loads as agreed with manufacturer. The stress engineer will
submit nozzle loads to the mechanical equipment engineer discipline lead for obtaining vendor
approval if nozzle loads exceed agreed upon load values. Vendor acceptance correspondence should
be included in the final stress analysis report.

10.0 SUPPORT DESIGN

All supports shall conform to Hargrove support standard unless otherwise specified.
Feasibility of alternative routing or additional support requirement is first checked in 3D model and
then discussed with concerned piping designer and C/S engineer when pipe routing changes or
supports are required to satisfy either code stresses or equipment nozzle loads.
All supports should be checked for Lift-off. If a support lifts off, one of the following should be
done:
a. Check code stresses in Alternate SUS case in Caesar II
b. Re-route pipe or relocate the support to avoid lift off
c. Add spring support
10.1 Pipe Spans and Guide Spacing
All lines shall be supported in accordance with the limitations set by the applicable piping
codes.
a. Generally dead weight deflection between supports should be limited to
• 5/8” for process piping (to insure >4HZ natural frequency)
• 1/8” for steam & flare piping (unless code notes otherwise).
b. Pipe support span table HAR-TBL-EN-PI-002 (see Appendix – B) can be utilized for
general guidance by the piping designer. Pipe guide spacing charts (see Appendix –
C) can be used for general guidance on placement of guides in both horizontal and
vertical pipe runs.
c. Pipe support span and support types should be adequately selected for piping prone
to vibration.
10.2 Trunnions
The piping codes require consideration of stresses in the pipe caused by attachments
welded to the pipe. Complex stress fields are created at the interface of the attachment and
the pipe.
Trunnions can be modeled in Caesar II to generate applied loads, and then checking the
developed stresses at the attachment by utilizing either an FEA program (NozzlePro) or
manual calculations (Kellogg Line Method).
For large axial loads or high stresses, FEA or Kellogg may still need to be used.
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Re-pads should be used on trunnions connecting to Sch.10S pipe.

10.3 Springs
The cold load should be designed to be within 25% of the hot load (within10% for rotating
equipment).
The cold load setting should be based on operating conditions, but the spring size should be
checked at all load cases to ensure all conditions are within the springs working range. For
constant supports, hot load and cold load are the same.
a. For F-type springs, horizontal loads should be maintained below 30% of the vertical
load with a maximum horizontal displacement of 1”
b. Include weight of hardware between pipe and spring (clamps, shoes, etc.)
c. Hydrostatic test loads with travel stop in place should not exceed 2 times the
maximum capacity of the spring. If exceeds then provide temporary rigid support
for hydro test.
d. Include Lifting lugs for springs weighing more than 100 pounds.
e. Spring can data sheets shall be provided by the Stress Engineer including all ancillary
hardware required for installation and procurement.
f. Pipe stress engineer shall assign a specialty item number in the engineered support
list (HAR-XXXXXX-PI-LST-101) and detail datasheet of the spring with all
dimensions, accessories and ordering information shall be provided to piping design.
g. Spring Data sheet should indicate that the travel stops are to remain in place during
hydrotesting then removed before start-up. Also, the spring should be adjusted to
its marked hot load setting after the system is in normal operation.
h. Spring supports carrying heavy load (more than 20kips) shall use jacking bolts.
10.4 Rod Hanger
Piping systems supported primarily by rod hangers shall accommodate the rod’s rotation
and the consequent load impact on nearby equipment nozzles. Rod hanger lengths shall be
modeled in the piping stress analysis. The rotation of the rod hanger shall be checked and
shall not exceed 5 degrees during any of the operating, upset, relieving, etc., conditions.
External Loads on Equipment shall be considered for impact due to support rod rotation.
10.5 Large Diameter Pipe
Large diameter thin wall (D/T > 100) lines shall be analyzed for crushing loads at local stress
points and reinforced as necessary. Consideration shall be given to the use of partial re-pads
or saddle type supports for D/T >100 to minimize bearing stress.
The maximum allowable load at the support point (Pa) can be calculated by:
Pa = [Sh * (t^1.5) * b] / [1.8 * (R^0.5)] (lbs)
Sh = Hot allowable load (psi)
t = Effective wall thickness (including re-pad) (in)
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b = Bearing length of pipe (along the pipe axis) on the support structure (in)
R = Outside Radius (in)

11.0 DOCUMENTATION
Documentations shall be prepared as per below guidelines:
a. Documentation is required for category A & B lines. Documentation may be
required for category C lines but marked up stress isometric is minimum required
documentation for category C lines.
b. Stress markups on isometrics to be done electronically using Bluebeam Revu
Markup toolkit. (Available in CoP page). Minimum markup requirement for stress
isometrics is as below.
• XYZ coordinate stamp
• Design conditions (if line list is not available)
• Node numbers at
o Bends & SIFs
o Restraints
o Equipment connections
o Property change (Material, Design conditions, Refractory etc.)
• Specialty supports (springs, slide plates, snubbers…) shall be fully detailed
• All displacements >2”
• Change in routing
• Restraint types and locations (Clearly indicate any gap requirements on
guides, axial stops & hold downs)
• Relief Valve Thrust Force and Direction
• Battery limit boundary conditions
• Special notes for Piping Designer or C/S engineer
• Sheet numbers / continuation sheet number
Isometrics shall be arranged as per order of modeling in Caesar II.
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c. Calculation numbers shall be assigned to identify each analysis (example, FSA-001)

and the analysis files shall be stored in Project folder under Eng Dsgn  Pipe 
Calc  FSA-XXX

d. Stress analyst performs self-checking by following the check list (Template, HAR-
CKL-EN-PI-001)
e. After self-checking, stress analyst submits preliminary documentation for checking
and stores design data and analysis files in respective folders under FSA-XXX (refer
Appendix E) along with checklists and SDC files in “07. Checking” folder
f. Qualified checker assigned by resource lead or discipline lead checks the stress
calculations and provides comments on checklist as part of single discipline checking
process.
g. If EoR is other than discipline lead, then EoR is ideal candidate for checking the
calculations.
h. Stress analyst incorporates the comments provided by the checker and submits
back to checker for back checking of comments
i. Once stress comments are resolved and accepted by analyst and checker, single
discipline checking report (HAR-RPT-EN-QA-001) is signed by Checker, Discipline
Lead, EoR and Resource Lead.
j. If formal stress report is not required then Stress Report cover sheet (Template,
HAR-XXXXXX-PI-CAL-001), Restraint summary, Stress summary, Displacement
summary for Operating case shall be stored in “08. Stress Report” folder as listed in
Appendix-E as part of final documentation.

12.0 DELIVERABLES
Internal deliverables to be submitted to respective discipline lead via email registering the
communication email in respective New Forma project. Deliverable are delivered only after single
discipline checking process is complete and single discipline checking report (SDC) is signed.
12.1 To Piping Design
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Provide marked up stress isometrics back to piping design discipline lead along with any
engineered support details.
12.2 To Civil / Structure
Provide Restraint summary in excel sheets for all major load cases (identifying load case
names on spreadsheet) along with marked up stress isometrics and any engineered support
details shall be provided to civil / structure discipline lead engineer for piping load
consideration in their design.
12.3 To Mechanical
Communicate with Equipment engineer if vendor approval is required for nozzle loads.
12.4 To Client
Only if required contractually or requested by client, Stress analyst prepares final report
after single discipline checking process is complete.
Pipe stress discipline lead submits final report to client via Hargrove document control by
filling up transmittal request form and placing stress report in respective project folder
under Eng Dsgn  To Doc Cont folder
In absence of client specific requirement for report content, the final report should be a
single PDF file containing the below listed information in given order. Documents can be
combined into single PDF using Bluebeam Revu.
Sr. Name of Document
1 Cover Sheet (Template, HAR-XXXXXX-PI-CAL-001)
2 Project specific design basis (Template, HAR-XXXXXX-PI-DB-001)
3 CAESAR-II 3D Plot
4 Line List for this stress system (if Line list is not available then enter data on
cover sheet & apply design condition stamp on isometrics)
5 Marked up Stress P&ID (Highlight all lines in this stress package)
6 Stress Isometrics with nodes, support & modification mark-up (Use “Pipe Stress
Markup Tool Set.btx” in Bluebeam for markup)
7 Restraint Summary from CAESAR-II
8 Stress Summary (HYD, SUS, EXP, OCC)
9 Input Echo from CAESAR-II
10 Displacement Summary (Operating Case)
11 PSV Data Sheet
12 PSV Reaction Force Calculation Sheet (Template, HAR-FM-EN-PI-001)
13 Flange Evaluation Results
14 Equipment Nozzle Load Sheet
15 Nozzle Pro Results / WRC results / FEA calcs / API calculations
16 Equipment Data Sheet / Vendor Drawing
17 Hanger Table w/ Test
18 Spring Data Sheet / Spring Table
19 Expansion Joint Specification
20 Piping material specifications (pipe class)
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21 Trunnion check report (From FEPiipe or Kellog method)

22 Vendor or Project correspondence related to stress package
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13.0 APPENDIX A: COMBINATION OF LOAD CASES IN CAESAR-II

Combination of the load cases shall comply with the rules of the applicable piping code. Occasional
load cases and special load conditions need not to be considered simultaneously.
Analyst should define proper load cases in CAESAR-II. For different loads and temperatures possible
combinations are shown in example below.

Load case Remark

W Deadweight Weight of pipe, insulation, and media
HP Hydro Test Pressure
WW Water Filled Weight Weight of pipe, insulation, and water
WNC Weight no contents Weight of pipe and insulation
T1 up to T9 Temperature 1 - 9 Temperature
F1 up to F9 Force 1 - 9 External loads such as PSV reaction forces
P1 up to P9 Pressure 1 - 9 Pressure
Win1 up to Wind 1 - 4 Wind loads
Win4
D1 up to D9 Displacement 1 - 9 Thermal displacement at nozzles or displacement
due to settlements
U1 up to U3 Uniform Loads 1 - 3 e.g. Earthquake or snow loads
H Hanger loads Loads at spring and constant supports

Note: To comply with ASCE 7 requirements, you must include the load reduction factors in your load
cases for stress compliance.
W+P+T+0.6(WIND) Operating case with wind load (using the reduction factor) for computing stresses
W+P+T+(WIND) Operating case with wind load for computing loads on supports and deflections
W+P+T+0.7U1 Operating case with seismic load (using the reduction factor) for computing stresses
W+P+T+U1 Operating case with seismic load for computing loads on supports and deflections

Combined Loads Case Definition (Example)

T1 = Operating Temp P1 = Operating pressure
T2 = Max. Design Temp P2 = Design pressure
T3 = Min. Design Temp
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Case Case Load Case ombination Description Combine What to Check

No. Type Method in Output

1 HGR W Weight for Hanger loads -

2 HGR W+D1+T1+P1 Operating for hanger travel -

3 HGR W+D2+T2+P1 Operating for hanger travel -

4 HGR W+D3+T3+P1 Operating for hanger travel -

5 HYD WW+HP Weight of pipe and insulation (with test media) - Disp/Force/Stress
by check with air use WNC instead of WW.

6 SUS WNC+H Loads of pipe and insulation (without media) - Force / Stress

7 OPE W+D1+T1+P1+H Normal Operating Conditions - Disp/Force

8 OPE W+D2+T2+P2+H Max. Design Condition - Disp/Force

9 OPE W+D3+T3+P2+H Min. Design Condition - Disp/Force

10 SUS W+P1+H Weight + Operating Pressure + Spring Force - Disp/Force/Stress

11 SUS W+P2+H Weight + Design Pressure + Spring Force - Disp/Force/Stress

12 OPE W+D1+T1+P1+H+WIN1 Operating Condition + Wind 1 (+X dir.) - Disp/Force

13 OPE W+D1+T1+P1+H+WIN2 Operating Condition + Wind 2 (-X dir.) - Disp/Force

14 OPE W+D1+T1+P1+H+WIN3 Operating Condition + Wind 3 (+Z dir.) - Disp/Force

15 OPE W+D1+T1+P1+H+WIN4 Operating Condition + Wind 4 (-Z dir.) - Disp/Force

16 OPE W+D1+T1+P1+H+U1+U2 Operating Condition + Earthquake 1 (X & Y dir) - Disp/Force

17 OPE W+D1+T1+P1+H+U1-U2 Operating Condition + Earthquake 1 (X & Y dir) Disp/Force

18 OPE W+D1+T1+P1+H-U1+U2 Operating Condition + Earthquake 1 (X & Y dir) - Disp/Force

19 OPE W+D1+T1+P1+H-U1-U2 Operating Condition + Earthquake 1 (X & Y dir) Disp/Force

20 OPE W+D1+T1+P1+H+U3+U2 Operating Condition + Earthquake 1 (Z & Y dir) - Disp/Force

21 OPE W+D1+T1+P1+H+U3-U2 Operating Condition + Earthquake 1 (Z & Y dir) Disp/Force

22 OPE W+D1+T1+P1+H-U3+U2 Operating Condition + Earthquake 1 (Z & Y dir) Disp/Force

23 OPE W+D1+T1+P1+H-U3-U2 Operating Condition + Earthquake 1 (Z & Y dir) Disp/Force

24 OPE W+D1+T1+P1+H+F1 PSV reaction force or external force case 1 - Disp/Force

25 OPE W+D1+T1+P1+H+F2 PSV reaction force or external force case 2 - Disp/Force

26 OPE W+D1+T1+P1+H+F3 PSV reaction force or external force case 3 - Disp/Force

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27 EXP L7-L10 Thermal 1 + Disp 1 (Normal Operating) Algebraic Disp/Force/Stress

28 EXP L8-L11 Thermal 2 + Disp 2 (Max Design) Algebraic Disp/Force/Stress

29 EXP L9-L11 Thermal 3 + Disp 3 (Min Design) Algebraic Disp/Force/Stress

30 EXP L8-L9 Displacement Stress Range T2-T3 Algebraic Disp/Force/Stress

31 OCC L12-L7 Only Wind in +X Algebraic Disp/Force/Stress

32 OCC L13-L7 Only Wind in -X Algebraic Disp/Force/Stress

33 OCC L14-L7 Only Wind in +Z Algebraic Disp/Force/Stress

34 OCC L15-L7 Only Wind in -Z Algebraic Disp/Force/Stress

35 OCC L16-L7 Only Earthquake Algebraic Disp/Force/Stress

36 OCC L17-L7 Only Earthquake Algebraic Disp/Force/Stress

37 OCC L18-L7 Only Earthquake Algebraic Disp/Force/Stress

38 OCC L19-L7 Only Earthquake Algebraic Disp/Force/Stress

39 OCC L20-L7 Only Earthquake Algebraic Disp/Force/Stress

40 OCC L21-L7 Only Earthquake Algebraic Disp/Force/Stress

41 OCC L22-L7 Only Earthquake Algebraic Disp/Force/Stress

42 OCC L23-L7 Only Earthquake Algebraic Disp/Force/Stress

43 OCC L24-L7 Only Reaction force Algebraic Disp/Force/Stress

44 OCC L25-L7 Only Reaction force Algebraic Disp/Force/Stress

45 OCC L26-L7 Only Reaction force Algebraic Disp/Force/Stress

46 OCC L31+L10 Stress check for Wind Scalar Stress

Same combination as case 46 for cases 32 thru 45

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14.0 APPENDIX B: PIPE SPAN CHART

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15.0 APPENDIX C: PIPE GUIDE SPACING CHART

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16.0 APPENDIX D: STRESS ANALYSIS WORKFLOW

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17.0 APPENDIX E: FOLDER STRUCTURE