Expansion loop Design & Leg Support Design

Suyog S. Bhamare
Thermal Expansion

Thermal Expansion. Expressed as the coefficient of

linear expansion, thermal expansion is a ratio of the
change in length per degree of temperature, to a length
at a given standard temperature (such as room
temperature, or the freezing point of water). The units of
the coefficient are length of growth per unit length per
degree of temperature. The value of the coefficient
varies with temperature.
Thermal Expansion of Pipe:

All pipes will be installed at ambient temperature. Pipes carrying hot fluids such
as water or steam operate at higher temperatures. It follows that they expand,
especially in length, with an increase from ambient to working temperatures.
This will create stress upon certain areas within the distribution system, such as
pipe joints, which, in the extreme, could fracture. The amount of the expansion
is readily calculated using Equation 1 or read from an appropriate chart such as
Figure.
Expansion (mm)=LΔTα ----------------------1

Where:
L = Length of pipe between anchors (m)
DT = Temperature difference between ambient temperature and operating
temperatures (°C)
a = Expansion coefficient (mm/m °C) x 10-3
What is an Expansion Loop?
Bend (usually in the form of a horseshoe or ω which is inserted
in a pipe run to provide for the expansion of the pipe resulting
from a temperature change or A complete loop installed in a
pipeline to mitigate the effect of expansion or contraction of the
line.
 Types of loop

• U-Loop.

• Omega Loop.

• 3D-Loop

• O -Loop

Reasons For Expansion Loops

Expansion loops are installed to reduce or eliminate tension and
compression forces on pipe. If these forces are not reduced premature pipe
fracture can occur as the temperature changes.
Pipe way Layout Steps before deciding a Loop:

1. Determine approximate length of pipe way from plot plan.

2. Establish line sizes and temperatures.

3. Establish preliminary berthing..

4. Anchor all lines near the center of the pipe way.

5. Calculate line spacing at the corners.

6. If the line spacing is wasting berthing room at the turns, determine

which
lines are giving the most trouble.

7. Move the anchors of these lines (one line at a time) closer to the
corners.
(The line will now have two anchors).

8. Place one or more loops between these two anchors.

9. Size the loops to fit the available space .

GUIDELINES FOR LOOP SIZING

1.Use of loops shall be considered, as a rule, when a piping, whose temperature difference
between operating (including steam purging, etc.) and normal temperature conditions is
100°C or more, is running a long distance (as a rough rule, when the expansion of piping at
one side is larger than 40mm), on pipe racks or on sleepers. The use of loops shall also be
considered, when it is necessary to have a least amount of movement of the piping, even
though the temperature difference of the piping is 100°C or lower.

2. The shape of loop shall be, as a rule, horizontal loop, as far as there is no problem from
the view point of piping route. If horizontal loop cannot be arranged due to any problem,
such as the space, existing obstacles, etc., three dimensional loop shall be selected. The
height of loop (H) shall be about 0.75 - 2.5m, where the size of such obstacles, etc., shall be
taken into consideration.
3 The allowable maximum distance between loops is different, depending upon the
temperature and size of the piping, length of the loop, etc. However, in order to utilize
the space effectively, it is preferable, as a rule, to provide each of parallel running
piping with loops, in such a way that the position of loops is the same for each piping
and the distance between loops is 50m.

4 The expansion loop is usually located on the side of the hottest line.

5. The expansion loop, as a rule, should be located in the center of the distance between
two anchors.

6. The height of the expansion loop is normally twice the width. The exception to this
rule occurs when more than one line runs parallel in a common trench. The dimensions
of the loops for the additional line must be increased to allow nesting of the loops.
 Case Study on loop Calculation by using Nomograph:
Find the size of loop to absorbs expansion in 200 Ft of 12” Carbon steel pipe at
4000F.Assume width to height ratio.

Expansion (mm)=LΔTα ----------------------1

By using above formula total expansion is around 5.4 inch

Using the nomograph & assuming a straight line starting from 12 inch diameter &
through a 5.4 inch in expansion, read bend length L as 50 ft. Assume H=W ,then L= 2H
+W=50 ft.Thus H=W=17 Ft .

So that, Expansion loop sizing 17X17X17

Alternate Method for Loop sizing.
Multiple Loops

•It is impossible to make branch connections flexible enough.

•Spacing between branches and neighbouring lines or steel is
limited.
•When loop becomes too large to support or fit into space available.
•Anchor forces become too unbalanced and steel cannot be
economically braced
 PIPE RACKS-Expansion Loop
A pipe rack is the main artery of a process unit.
It connects all equipments with lines that cannot run
through adjacent areas.
Because it is located in the middle of most plants, the pipe
rack must be erected first before it becomes obstructed by
rows of equipment. The corresponding piping drawings are
also required early for the same reason.
This vital area requires considerable planning and
coordination with other technology groups regarding
construction because costs are so high.
Although conducting the final stress analysis is the
responsibility of pipe stress engineer, the pipe rack designer
makes preliminary calculations using nomograms to ensure
that the design will not require major rework during the
formal stress check. The steps are illustrated in the next
slide -
Step-1 : Establishing potential flexibility problems.
The lines that would most likely require expansion
loops should be defined. Steam header in the top
level of pipe racks is such example.
Step-2 : Determining line growth. The growth of such utility
headers should be determined by multiplying the coefficient
of thermal expansion by the length of the line. The coeff of
expansion is based on a particular metal operating at a
specific temperature. Upset temperatures take precedence
over operating temperatures.
Step-3 : Determine whether one anchor will suffice. Assuming that the
anchor is located in the centre of the header, the designer should
calculate the growth of various branches to determine whether they have
enough flexibility to absorb the header growth. If not, two anchor points
at approximately one-fourth of the distance from each end of the header
should be tried. Using the nomogram, the designer can calculate the
amount of expansion leg required to satisfy all flexibility requirements.
Step-4 : Arranging the lines in proper sequence. The line that
requires the largest leg must be located on the outside of the
loop. Placing the headers along one side of the pipe rack
allows the expansion loops to sit with a slight overhang along
the adjacent side of pipe rack.
Case Study-Thermal Load
Case Study-Allowable Stress Range
 Flexibility Analysis
B31.3-319.4.2 Formal Analysis Requirements
(a) Any piping system which does not meet the criteria in Para.
319.4.1 shall be analyzed by a simplified, approximate, or
comprehensive method of analysis, as appropriate.
(b) A simplified or approximate method may be applied only if
used within the range of configurations for which its adequacy
has been demonstrated.
(c) Acceptable comprehensive methods of analysis include
analytical and chart methods which provide an evaluation of
the forces, moments, and stresses caused by displacement
strains (see Para. 319.2.1).
(d) Comprehensive analysis shall take into account stress
intensification factors for any component other
Case Study-Flexibility Analysis.
Case Study-Leg Design
Stress Calculation
Case Study-Expansion Stress
Nomograph Method-Guided Cantilever Method