Professional Documents
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STRESS ANALYSIS
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 1 of 18
Issue 02
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
1.
2.
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 2 of 18
Issue 02
INTRODUCTION
3
NORMATIVE REFERENCES
3
2.1
BASIC CODES .................................................................................................................... 3
2.2
REFERENCE STANDARDS .................................................................................................... 3
2.3
CLIENTS PROJECT SPECIFICATIONS ................................................................................... 3
3. SCOPE OF STRESS ANALYSIS VERIFICATIONS
4
4. CATEGORIES OF LINES AND STRESS ANALYSIS LEVELS
4
4.1
CATEGORY 1 ..................................................................................................................... 4
4.2
CATEGORY 2 ..................................................................................................................... 4
4.3
CATEGORY 3 ..................................................................................................................... 4
5. ACTIONS COMING FROM STRESS ANALYSIS VERIFICATION
5
6. DEFINITION OF SIGNIFICANT ACTIONS FOR STRESS ANALYSIS
CALCULATIONS
5
6.1
WEIGHT ............................................................................................................................ 6
6.2
TEMPERATURE .................................................................................................................. 6
6.2.1 Definitions .................................................................................................................... 6
6.2.2 Flexibility analysis........................................................................................................ 6
6.2.3 Equipment and machines reactions ............................................................................... 7
6.2.4 Flanged couplings loads ............................................................................................... 7
6.2.5 Spring supports sizing................................................................................................... 7
6.3
PRESSURE.......................................................................................................................... 7
6.4
DISPLACEMENT OF RESTRAINTS (DIS) ............................................................................... 8
6.5
OCCASIONAL LOADS ......................................................................................................... 8
6.5.1 Wind ............................................................................................................................. 8
6.5.2 Earthquake ................................................................................................................... 8
6.6
TEST CONDITION VERIFICATION ...................................................................................... 10
6.7
ALTERNATIVE CONDITION ................................................................................................ 10
6.8
DISPLACEMENTS AT BATTERY LIMITS .............................................................................. 10
6.9
LOAD COMBINATION CASES ............................................................................................ 10
7. PULSATION STUDY
11
8. LEAKAGE ANALYSIS FOR FLANGES
12
9. COEFFICIENT OF STATIC FRICTION
12
10. SPRING SUPPORT
12
11. EXPANSION JOINTS
13
12. VERIFICATION OF EQUIPMENT AND MACHINES REACTIONS
13
13. LOADS TRANSMISSION TO CIVIL DEPARTMENT
14
14. STRESS ANALYSIS REPORT
15
15. GENERAL REQUIREMENTS FOR NUMERICAL MODEL AND FOR CALCULATION
15
APPENDIX 1: CATEGORIES OF LINES ................................................................................. 16
APPENDIX 2: TABLE FOR ALLOWABLE EQUIPMENT NOZZLE LOADS ......................... 18
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
1.
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 3 of 18
Issue 02
INTRODUCTION
Scope of the present document is to explain the practices establishing the minimum requirements
that the piping stress analyst shall adhere to when performing activities intended to ensure
adequate engineering review of piping systems. The general scope of these activities is to verify
that every piping arrangement is sufficiently flexible to allow each line to thermally expand or
contract without overstressing pipes or connected equipment, and adequately supported so that no
damage occurs due to loads resulting from weight, pressure, wind, earthquake, shocks, foundation
settlement etc. The purpose of this specification is to ensure the sound and uniform approach to the
review of the mechanical safety of piping and related systems, and to give guidelines to producing
evidence that this has been done satisfactorily.
2.
NORMATIVE REFERENCES
2.1
Basic Codes
The following ASME Code shall be entirely applied as the basis of the piping system stress analysis
in conjunction with this specification.
ASME B31.3 Process Piping
2.2
Reference Standards
The following standards (according to &ZA-A-LX 0001 Codes & Standards for Olefinas III y
Polietilenos Ana Maria Campos Complex) shall be applied in conjunction with the requirements set
forth in this specification.
ANSI B16.5
API 560
API 610
API 611
API 617
API 618
API 650
API 660
API 661
NEMA SM 23
2.3
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
3.
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 4 of 18
Issue 02
To identify, basing on the criteria described in paragraph 4, all those piping systems that are
critical from the thermal behaviour point of view, or require deep verifications because of
particular operating conditions.
To identify according to the different grades of line criticality the most suitable verification
method.
4.
to verify that the maximum stress levels are below the maximum allowable values stated
by the governing code for the different load combinations;
to verify that reaction forces on machines and equipment nozzles are below the limits
described in paragraph 12;
to calculate the loads transferred to the structures by the piping supports, in order to
allow the civil designer to verify them;
to verify that the piping thermal expansion or contraction will not cause interference with
adjacent pipes and structures.
For piping systems belonging to the categories described in paragraphs 4.1 and 4.2, to
perform visual check or simplified analysis based on the routing of the line.
All pipes of the plant shall be reviewed during the design. The level of investigation can be more or
less detailed as specified below, according to the category each line belongs to.
4.1
Category 1
4.2
Category 2
4.3
Category 3
Formal computer analysis (by means of calculation software CAESAR II) shall be performed on
lines belonging to this category taking into account the pipe diameter, the maximum temperature
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 5 of 18
Issue 02
expected in any condition, the type of equipment or machine the pipe is connected to, the type of
fluid, the pipe material. A report of this analysis shall be produced according to what specified in
paragraph 13.
This category includes:
All the lines belonging to this category shall be grouped in stress systems and listed in a Stress
Critical Line List indicating all relevant information for each line involved in the analysis.
5.
The stress analysis results may require changes of the analyzed piping system. These changes,
always substantiated by project savings, process and piping requirements, may include:
6.
The computer-aided analysis shall take into account different internal and external actions, whose
effects in terms of stress and loads on restraints have to be properly combined.
International system of S.I. units shall be used. Exceptions are the following: pressure units in
bar(g) and temperature units in Celsius degrees (C).
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
6.1
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 6 of 18
Issue 02
Weight
Weight of piping and its components, including internal fluids and insulation, shall be considered as
uniform distributed loads. Other weights as flange, valves or similar can be considered as
concentrated loads.
Special consideration shall be given to possible alternative values for fluid density. All possible
values shall be defined by Process Department and listed in the Line List. For each possible density
value, Process Department shall also define wheter corresponding fluid weight has to be
considered as a sustained load or as an occasional one (see paragraph 6.5).
6.2
Temperature
6.2.1
Definitions
Tworst
Tmax
Tope
Tdes
Tinst
Tworst is the most severe temperature scenario that the piping system will be subject to during its
operating life, and it shall be evaluated considering normal operating condition and all possible
alternative conditions (e.g. steam-out, regeneration, shutdown, start-up etc.). Tworst shall be equal to
Tmax (or to Tdes, if the value of Tmax is not available).
Tinst (installation temperature) shall be assumed to be +28 C, i.e. the average annual temperature
according to document &ZA-A-SB 0001 "Meteorological Conditions for Olefinas III y Polietilenos
Ana Maria Campos".
Note: metal temperature due to solar radiation shall be assumed to be +87 C for uninsulated lines
subject to solar exposition.
6.2.2
Flexibility analysis
The analysis shall be implemented using the worst differential temperature T, where:
T = Tworst - Tinst
For line connected to pumps, temperature decay in the stand-by portion of piping (without warming
by-pass) shall be considered as per the following scheme:
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 7 of 18
Issue 02
The reactions on equipment and machines nozzles shall be calculated in operating condition, using
the design differential temperature T, where:
T = Tope - Tinst
6.2.4
The forces and moments acting on flange connection shall be calculated in design condition, using
the design differential temperature T, where:
T = Tope - Tinst
6.2.5
The spring supports shall be set basing on load and travel in operating condition, using operating
differential temperature T, where:
T = Tope - Tinst
Vendor shall verify that the selected spring support allows the different travel occurring in the worst
scenario. For this purpose, spring travel in alternative thermal conditions shall be transmitted to
Vendor in springs data sheet.
6.3
Pressure
Calculations shall consider the design pressure as per plant Line List.
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
6.4
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 8 of 18
Issue 02
Movement of restraints (equipment nozzles or others) due to thermal expansion or other causes
(e.g. settlement of large equipment foundations) shall be considered in the analysis of piping
systems.
6.5
Occasional Loads
Occasional loads which piping may be subject to shall be taken into account as static loads when
verifying longitudinal stresses. A proper multiplicative factor for the allowable stress shall be
considered, as per Code requirements.
Occasional loads may include:
wind loads;
earthquake loads;
loads caused by safety valves opening;
impulsive loads (e.g. slug flow or water hammer, if specified by Process Department).
Special attention has to be paid to the calculation of distributed forces due to wind and earthquake.
6.5.1
Wind
Wind load shall be considered in the design of this plant according to document &ZA-A-SB 0001
and to Code ASCE 7-05.
Wind load shall be applied as a static load, in the horizontal direction producing the worst conditions
in terms of loads for the piping system, its supports and equipment nozzles.
The shape factor considering the pipe surface properties shall be 0,7 for Caesar calculation.
The basic values to be considered in the application of ASCE code are the following:
6.5.2
= 33.5 m/sec
= 3 (exposure C; open terrain with scattered obstruction)
= 0.03 (standard value)
=3
= 1.15 (category III / IV)
Earthquake
The earthquake load shall be considered in the design of this plant: it shall be applied to piping
systems as an equivalent static load acting in each of the four horizontal directions North, South,
East and West (not simultaneously). The eartquake load is calculated according to paragraph
13.3.1 of Code ASCE 7-05. The coefficient of ground maximum acceleration, which is necessary for
the calculation of the seismic force, is determined according to relevant Venezuelan Code Covenin
3621:2000.
is calculated as a fraction of the weight
As per ASCE 7-05, the horizontal seismic design force
by the following formula:
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
Client : POLIOLEFINAS
INTERNACIONALES C.A.
LDPE Plant
Page 9 of 18
Issue 02
is the piping element elevation with respect to grade, while is the structure roof elevation: in
is considered as 1.
order to guarantee a conservative approach, the ratio
The applicable component importance factor is 1.50, as per paragraph 13.1.3 of ASCE 7-05.
and
are determined from table 13.6-1:
The parameters
is the correction factor of the horizontal acceleration coefficient, depending on the soil
type
, is the coefficient of ground maximum acceleration, which can be calculated as the ratio
of the ground maximum horizontal acceleration to the gravity acceleration - (
-).
where the parameters and 4 can be obtained from the Map of Seismic Hazard (see figures 1 and
2 of paragraph 7.1), and /0 is the annual probability of exceedance, given in Table 1 depending on
the degree of risk.
Basing on the location of the plant in the seismic risk charts, the following values can be considered
for and 4:
4
For a degree of risk B, /0 is equal to
29
56 7 8
#
and
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 10 of 18
Issue 02
According to the final report by Tivenca Soil study for detailed engineering project concerning site
preparation for the Ana Maria Campos Olefin III and Polyethilene Plant, the area associated with
the project presents a category S2 spectral form, which means !
according to table 3 of
Covenin 3621:2000. For a damping factor " #:, the following value can be calculated for ! :
!
#
can be assumed as follows:
6.6
An additional load case shall be foreseen when the Line List indicates that hydraulic test is required.
In this case the calculations shall be performed considering erection temperature, internal fluid
weight, test pressure, excluding insulation weight and corrosion.
Results of the analysis may require hydraulic test on the ground or the use of temporary supports,
in order to avoid overloads on equipment and structures.
6.7
Alternative condition
Additional load cases shall be foreseen when the Line List indicates design alternative conditions
(e.g. steam-out, regeneration etc.).
Steam-out conditions are defined in Equipment Process Data Sheets.
6.8
As a general rule, axial stops and guides will be provided on pipes near Battery Limits to reduce as
much as possible piping displacements on the Battery Limit points.
6.9
The calculation of forces and moments acting on restrains and of the stress level of the piping
system shall be based on the following load combinations, according the prescriptions stated by the
code ASME B31.3 2002 Edition:
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
No.
Client : POLIOLEFINAS
INTERNACIONALES C.A.
LDPE Plant
Load Cases
L1
W+P1+T1+D1+H
L2
W+P1+T2+D2+H
L3
W+P1+T3+D3+H
L4 W+P1+T1+D1+H+WIND
L5
W+P1+T1+D1+H+U
L6
W+P1+T1+D1+H+F
L7
W+P1+H
L8
WW+HP
L9
L1-L7
L10
L2-L7
L11
L3-L7
L12
L4-L1
L13
L5-L1
L14
L6-L1
L15
L12+L7
L16
L13+L7
L17
L14+L7
Stress
Type
OPE
OPE
OPE
OPE
OPE
OPE
SUS
HYD
EXP
EXP
EXP
OCC
OCC
OCC
OCC
OCC
OCC
Page 11 of 18
Issue 02
Comb.
Method
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Algebraic
Scalar
Scalar
Scalar
Load Type
where:
W
= weight
WW
= water filled weight
T1, T2, T3 = temperature
P1
= pressure
HP
= hydrotest pressure
D1, D2, D3 = displacements
H
= concentrated permanent forces (such as spring forces)
F
= external forces
WIND
= wind loads
U
= uniform loads (earthquake)
7.
PULSATION STUDY
All process lines connected to reciprocating compressors must be analyzed by the equipment
Vendor according to API 618.
The Vendor will perform acoustical and mechanical analysis, in order to prevent the occurrence of
any resonance phenomena by the optimization of piping routing and supports.
In order to provide the Vendor with all necessary information, TCM will collect and transmit the
following documents:
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 12 of 18
Issue 02
After the analysis, the Vendor shall prepare a calculation report detailing all relevant comments.
TCM will then update piping routing and supports accordingly.
8.
To avoid leakage in flanges, bending moments and forces on flanges with rating 300#, diameter
DN 12 and T 250 C, shall be limited according to Equivalent Pressure Method: the
equivalent pressure shall be limited to 1.5 times the rating allowable pressure. If this analysis gives
negative result, detailed investigation shall be done according to criteria mentioned in Appendix S,
ASME Section VIII Division 1.
T will be evaluated as per paragraph 6.2.4.
9.
Friction coefficient must be considered to calculate the horizontal reactions due to the vertical force
on each resting point; the values to be considered shall be those reported in the table below:
Surfaces
Steel on steel
Steel on Teflon or graphite
10.
SPRING SUPPORT
Spring supports shall be used to support dead weight only. Load variation shall be in accordance
with the following limits:
Variation
15 - 20%
10 - 15%
8 - 12%
In all other cases, load variation shall be limited within the maximum value of 25%.
All the spring supports defined for the plant shall be listed in data sheets showing all the functional
data.
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
11.
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 13 of 18
Issue 02
EXPANSION JOINTS
Line flexibility requirements shall be as far as possible satisfied by changes of direction, loops etc.
The use of expansion joints shall be limited to those cases in which routing modifications are
difficult or impossible for the following reasons:
In any case such solution shall be preventively submitted to approval by Process Department.
All the expansion joints defined for the plant shall be listed in data sheets showing all the functional
data.
The design of the metallic expansion joints shall comply with the requirements stated by EJEMA
Standard.
12.
Equipment reactions shall be calculated considering the piping thermal expansion in operating
condition, other external forces acting on the piping (weight, friction) and the displacements
imposed to the piping by connected equipment.
The allowable forces and moments on equipment nozzles shall comply with the following applicable
standards, when manufacturers data are not available. In any case the manufacturers specified
values shall govern.
Loads on nozzles eventually exceeding allowable loads defined in the following paragraphs shall be
transmitted to equipment Vendor for verification and approval.
a) Pumps designed with API 610
(1) The nozzle loads on centrifugal pumps with suction nozzles of NPS 16 nominal diameter or
less shall comply with the load criteria of API 610.
(2) For nozzle diameters greater than NPS 16, the allowable load values shall be obtained from
the manufacturer.
b) Compressors designed with API 617
Nozzle loads shall comply with the load criteria of API 617.
c) Pressure Vessels and Heat Exchangers
Allowable loads on nozzles of pressure and non-pressure equipment shall be in accordance
with TM 300.1 (see appendix 2 for quick reference).
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
13.
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 14 of 18
Issue 02
Once all critical systems to be supported by one structure have been analyzed, piping loads on this
structure have to be transmitted to Civil Department for check and approval. For this purpose, a
new document shall be issued, basing on the structure one-line drawing (document 3507-AI-DUxxx). Stress Engineer shall comment this document with all significant piping loads due to critical
systems, by means of the following tables, to be filled in for each support.
VL
VL (test)
HL N-S
HL E-W
HL N-S (W)
HL E-W (W)
HL N-S (E)
HL E-W (E)
VL (SF)
HL N-S (SF)
HL E-W (SF)
VL (OD)
HL N-S (OD)
HL E-W (SF)
Wind and earthquake loads have to be considered as net, i.e. not including weight of pipe /
insulation / fluid content nor the effect of thermal expansion.
The Civil document, so commented with piping loads, shall be issued by Stress Engineer as a new
document, whose number will be 3507-XX-DF-xxx.
If a preliminary issue of this XX-DF document is needed, including only some of the critical lines to
be supported by the structure, then this document must include a note clearly detailing which lines
have been taken into consideration.
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
14.
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 15 of 18
Issue 02
Input and output files shall be in MM units. All the output report shall be in 132 columns type.
15.
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 16 of 18
24"
22"
20"
18"
16"
14"
12"
10"
8"
6"
4"
2"
1"
-46
100
200
300
T [C]
category I
category II
T = Tdes Tinst
category III
400
Issue 02
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 17 of 18
Issue 02
T
-46C or 250 C
200 C
150 C
1200 40 NPS
9
with:
NPS 3
All other lines connected to these machines belong to category 2.
3507-XH-SG-002
PROJECT DOCUMENT NUMBER
&TCM-L-SE-000002.200
Plant:
LDPE Plant
Client : POLIOLEFINAS
INTERNACIONALES C.A.
Page 18 of 18
Issue 02
MOMENTS [Nm]
NPS
DN
TL
TC
ML
MC
MT
3
4
6
8
10
12
14
16
18
20
24
80
100
150
200
250
300
350
400
450
500
600
1500
2100
4600
6000
7600
9200
10800
14600
18500
22300
30000
1500
2100
4600
6000
7600
9200
10800
14600
18500
22300
30000
1500
2100
4600
6000
7600
9200
10800
14600
18500
22300
30000
600
1100
3400
5700
6900
8000
9200
11300
13500
15600
20000
600
1100
3400
5700
6900
8000
9200
11300
13500
15600
20000
600
1100
3400
5700
6900
8000
9200
11300
13500
15600
20000
The loads on this table are valid for equipment having a corroded medium radius R = 1000 mm and
a shell thickness t = 10 mm, net of corrosion allowance and material mill tolerance.
For equipment with different radius and thickness, the above loads shall be multiplied by the
following factor:
=
<0 =
For equipment in stainless steel or in special materials (Ni, Cu, Al, Ti alloys etc.), table values shall
be decreased by 25%.
For nozzles smaller than 3 no check shall be made, because relevant loads have to be considered
as negligible.
For nozzles whose size is not listed in above table and in all cases where loads exceed reported
values, evaluation by the Equipment Engineer is required.
For high pressure vessels the allowable nozzle loads shall be obtained from the manufacturer.