Flexibility Analysis for High

Temperature Piping System Case Study for Combined Cycle

Power Plant.

What is Pipe ?

It is a Tubular item made of metal, plastic, glass etc. meant for conveying Liquid, Gas or
any thing that flows.
It is a very important component for any industrial plant. And its engineering plays a
major part in overall engineering of a Plant

High Temperature Piping

In Power plant there are some piping which carries steam at high pressure and
temperature.. These pipes carries the main cycle steam and water of the steam power
plant.

Pipe material selection - to withstand the high pressure and high temperature.

Steam pipes run at very high temperature and the hot pipes expand.There should be
enough flexibility in these pipes so that pipe can itself withstand this thermal loading
and high loads should not transferred to the nozzles of Turbine or Pumps.

Pipe Stress Analysis

This process of checking the stress developed in the piping due to various loading is called Pipe Stress Analysis/Flexibility analysis.

It is a discipline highly interrelated with piping layout and pipe support design and normally associated with analysis of stresses in a piping
system, primarily due to thermal expansion or contraction. Codes and standards establish the minimum requirements of stress analysis.

The objective of the Pipe flexibility analysis is to ensure safety against failure of the piping material or anchor points from overstress.

Check pipe stresses with governing codes (as Design Base Document) .

Support load & movement for various loading conditions.

Check the terminal point loading (Forces & Moments) generated from pipe to the connected equipment.

Types of Loads

Sustained Loads
Dead Weight (Weight Of
Pipe, Fittings, Fluid in Pipe,
Piping Components valves,
valve Operators, flanges so
on.)

Dead Weight
Thermal Expansion and
contraction effect
Effects of Support, anchor and
thermal movements
Internal and external loadings

Thermal Expansion Loads

Due to the Temperature

Occasional Loads
Seismic
Wind
Snow and etc.,

Also loads on piping can be

classified as
Static Loads

Dynamic Loads

Impact forces
Wind Load
Seismic Load
Steam & Water Hammer effects
Discharge Loads

Stresses in Piping
Hoops

Stress
Longitudinal Stress
Axial Stress
Radial Stress
Bending Stress
Torsion
The failure of structural part occurs when a certain function of the
stress or strain components reaches a critical value. The peculiarity
of the piping system is such that, there are possibilities of every
possible stresses being generated in it

Stresses in Piping..Contd.

Circumferential stresses - Due to internal pressure

Bending and torsional stresses - Due to dead load, snow and ice,
wind or earthquake.
Primary stresses - Due to external effects are the direct
longitudinal
Due to pressure inside the pipe - Three-dimensional stresses in
longitudinal, circumferential and radial direction are generated.
Bending and torsional stress - Due to thermal expansion or
contraction because of temperature variations, bending and
torsional stress are generated.
There are the direct, bending and torsional stresses - Due to the
restrained thermal loadings (the restrained thermal analysis, the external
forces being supplied in this case by the line of anchors and other restraints.)

Methods of Flexibility Analysis

Code Method
Approximate Methods
Guided Cantilever Method
Chart Solutions
Mitchell Bridge Method

Exact Analytical Methods

Simplified Kellogg's Method
General Kellogg's Method
Using Finite Element Technique

Model Tests

Finite Element Method

It is a numerical method of solution of complex problems, which is

based on the general principle of "going from part to whole". Finite
element method converts a continuous system into a discrete
system. (Linear, three dimensional finite analysis program)

Derivation of finite element equations

[K] * {u} = {F}

where,
[K]
{U}
{F}

= global stiffness matrix,

= global displacement vector,
= global load vector

Pipe Flexibility Analysis

Inputs and Various Steps in

Flexibility Analysis

Geometric layout of Pipe

Pipe supporting configuration
Pipe Diameter and Thickness
Pressure inside Pipe
Cold and Hot temperatures of Pipe
Weight of Pipe and insulation
Weight of carrying Fluid
Pipe material Property (Youngs
Modulus, Thermal Expansion
Coefficient)

Thrust on pipe due to

blowing wind.
Thrust on pipe due to
earthquake
Load of Snow on pipe
Any transient loading like
Steam Hammer load
Any other load on the
piping

Pipe Flexibility AnalysisContd.

Piping Analysis Software

PIPSYS is a PC-based computer program. This software package is an
engineering tool used in the mechanical design and analysis of piping systems.
There are many other commercial software available are SAP-IV, COSMOS/M,
NISA, CAESAR-II & CAE PIPE.
Outputs
Stress of the pipe at various loading conditions
Load at various supports and restrains.
Movement of pipe at support locations
Pipe terminal point (anchor, equipment ) loading.

PIPSYS
The integrated Piping Analysis Software Program (PIPSYS) combines a
linear, three dimensional finite analysis program with menu-driven interactive
modules to pre and post process data for analysis and stress evaluation of
piping systems.

Piping Flexibility

The major requirements in high temperature piping design is to

provide adequate flexibility for in the piping system to allow the
thermal expansion of the pipe without causing excessive stresses and
without exceeding the terminal equipment allowable loadings.

Flexibility can be provided using Expansion loops, offsets, bends, etc.,

In piping designing, elbows, Bends, and Pipe Expansion Loops
normally provide adequate flexibility for thermal expansion.
The stress can be reduced by introducing an expansion loop.
Expansion loops provided in the pipe length perpendicular to the
direction of straight pipe.
The expansion of straight pipe will be accommodated between the
anchors by flexing the loop legs, thus reducing the stress in the

pipe and loading on anchor.

Expansion Loops

Consideration for Piping Flexibility

Avoid the use of a straight pipe run of pipe between two-equipment

connection or between two anchor points.
A piping system between two anchor points in a single plane shall have as
a minimum configuration L-Shaped consisting of two runs of pipe and a
single elbow.
A piping system between two anchor points with the piping in two planes
may consist of Two L-Shaped runs of pipe. For e.g. One L-shaped run in
the horizontal plane and another in vertical plane.
A three-plane configuration may consist of a series of L-shaped runs or Ushaped expansion loops designed into the normal routing of the system.
For high temperature piping following minimum consideration are required
to ensure adequate flexibility :
Adequate developed length of piping system between anchors/
equipment connection with in the physical design constraints as
functional design requirements.

Consideration for Piping

Flexibility.Contd..
Provision of flexible supports, when up or down movement of pipe at support
location will be made possible
Provide single or multi direction restrain at strategic location to guide the pipe
thermal expansion in a predictable manner and also to constraint where
necessary.
Further guides and restrain help to the control the excessive pipe rotation and
resulting the stress in the pipe on moments on the equipment nozzle.
Provide flexible supports in vertical raiser.

For systems consisting of large diameter main and numerous smaller branch lines,
the designer must ascertain that the branches are flexible enough to with stand the
expansion in the main header.
Systems that are purged by steam or hot gas must be reviewed to assure that they
will be flexible during the purging operation.
Closed relief valve and hot blow down systems should be given special attentions.

Flexibility of Piping - Example

Flexibility of Piping - Example

Expansion Loop

Types of Pipe Supports

Constant Load Spring

There are three general types

Rigid type (no flexibility in the
direction of restrain)

Spring type (Allows pipe

movement in direction of loading)

Dynamic Support (Degree of

restrain depends on acceleration
of load)

There are two types of spring support

Variable load type, here support load changes as the pipe

moves.

Constant load support, the load remains constant within some

range of movement.

Rigid Support

Variable Spring

Rigid Hanger

Dynamic Support,
Snubber
Rigid Support

Case Study for Combined Cycle

Power Plant
Main Steam Piping System
The High Pressure (HP) steam system is designed per
ASME-B31.1(Power Piping Code) to convey HP
superheated steam, from the HRSG HP superheater
outlet to the high pressure section of the steam
turbine. HP steam line is provided with a bypass line,
with a combined pressure reducing and steam
desuperheating valve and is connected to the
Condenser.
Normal Operation
Start-Up/Shutdown Operation

Piping Material Selection

Piping material selection is based on established industry practices for the

temperature, pressures, services and fluid type

General water and steam services less than 750 F

Steam Piping above 750 F less than 955 F
Steam piping above 955 F to 1050 F
Steam piping above 1051 F to 1200 F
Flashing heater drain service
Mild corrosive service
Severe corrosive service
Low pressure and temperature
Concentrated acid handling systems
Fire protection

ASTM A 106 Grade B or A53 Gr. B

ASTM A 335 Grade P11
ASTM A 335 Grade P 22
ASTM A 335 Grade P 91
ASTM A 335 Grade P5
ASTM A 312 or A 367, Grade TP304
ASTM A 312 or A 367, Grade TP316
ASTM A-53 Grade B
Alloy 20 or HDPE / PVC / Rubber lined
Carbon steel

Design data
Pipe Size
=
8 inches for Main Steam Pipe
Pipe Thickness
=
160 Sch

Insulation Thickness =
7.5 inches

Pipe size
=
24 inches for Bypass connection

Pipe Thickness
=
STD

Insulation Thickness =
2.5 inches

Design Temperature =
955.4 F

Design Pressure
=
1450 psi

Pipe Material
=
ASTM A335 P22

Insulation Material
=
Calcium silicate per ASTM C533 for heat retention

Pipe Construction
=
Seamless

Flange type
=
Not Allowed
Fittings Greater than 2 inch

ASTM Spec.
=
A234 WP22

ASME STD. Type

=
B16.9, B16.28

Type
=
Butt Weld
Fittings Less than 2 inch

ASTM Spec.
=
A182 F22

ASME STD. Type

=
B16.11

Rating =
9000 Class

Type
=
Socket Weld

Attemperator weight =
1322.5 lbs per 7.87ft

Stress/Node Isometric

Analysis Methodology

The Piping System is considered as an assembly of many pipe segments connected by analytical node points.
The stress is computed based on internal forces and moments in each segment at all node points.
The reactions at each pipe support location are calculated; force equilibrium check is made at all node on
support points.
The stress value as calculated in the analysis for sustained load and thermal expansion load at each node will
be verified as per ASME B31.1 code equations for code compliance.

Dead weight Analysis

The PIPSYS checks the node formation and end connection of fittings, if it is properly sequenced it will further
proceed by forming a matrix for further analysis else error will be indicated for the specified Node and the
same should be corrected.
it is checking the dead weight supporting is within the permissible limit. If the pipe is not properly supported in
dead weight the support location should be changed to minimize the sag.
NODE TYPE FACTOR
STRESS IN PSI DISPLACEMENTS IN INCHES (GLOBAL COORDINATE)
I
(I*M)/Z
X
Y
Z
-------------------------------------------------------------------5 7
1.46
1389.
0.000 0.000 0.000
10 1
1.00
373.
0.000 -0.010 -0.001

Pipe Behaviour In Thermal Condition - Iteration -I

Nodes Failing

Nodes Failing

Maximum stressed Node - Iteration I

NODE NODE STRESS ALLOWABLE RATIO

TYPE
(PSI)
STRESS(PSI)
95
8
144000.
29180.
4.935
320
1
60800.
29028.
2.095
50
1
42200.
28083.
1.503
5
7
33000.
28619.
1.153
55
8
31400.
28639.
1.096
Ratio are more than 1, means that the stresses are exceeding the allowable stress limits and thus the nodes get
fails.

Equipment Nozzle reaction

Hrsg
LOAD CASE
HOT & WEIGHT
COLD & WEIGHT

FORCES (LBS)
FR = 4082.
FR = 3516.

MOMENTS (FT-LBS)
MR = 60244.
MR = 72069

Turbine.
HOT & WEIGHT
COLD & WEIGHT

FR = 6068.
FR = 6679.

MR = 36673.
MR = 44044.

FR = 1102.
FR = 1734.

MR = 6646.
MR = 9026.

Condenser
HOT & WEIGHT
COLD & WEIGHT

Pipe Behaviour In Thermal Condition - Iteration -II

Expansion Loops

Guide Support

Spring Hanger

Maximum stressed Node - Iteration II

NODE NODE
TYPE

STRESS
(PSI)

325
305
5
330
55
95

24500.
21700.
19800.
18600.
16000.
14400.

11
8
7
7
8
8

ALLOWABLE RATIO
STRESS(PSI)

29443.
29332.
28606.
29494.
28651.
29015.

Equipment Nozzle reaction

Hrsg
LOAD CASE
HOT & WEIGHT
COLD & WEIGHT
Turbine.
HOT & WEIGHT
COLD & WEIGHT
Condenser
HOT & WEIGHT
COLD & WEIGHT

FORCES (LBS)
FR = 3924.
FR = 3260.

MOMENTS (FT-LBS)
MR = 56488.
MR = 67373

FR = 5983.
FR = 6503.

MR = 33526.
MR = 40128

FR = 1109.
FR = 1674.

MR = 9508.
MR = 12032.

0.832
0.740
0.692
0.631
0.558
0.496

Final Iteration

As the same Lot of trail and error iteration has been done to keep the pipe within
permissible limit in dead weight, minimum stresses at all nodes and all the three
equipment nozzles within the allowable limits as specified by the manufacturer of the
same.

Finally by doing lot of iteration the best solution has arrived which gives

Minimum stresses in Piping

Meets the code limits and
Meets the Equipment forces and moments.

Conclusion
As seen in the case study in detail, the piping stress analysis checks with

The Acceptance of piping system per applicable design code,

Requirement related to equipment limitation and

which ensures

The Safety of piping and piping components against failure

Maintain system operability
to comply with legislation / Indian boiler regulation
the piping is well supported and does not sag or deflect in an unsightly way under its
own weight
the deflections are well controlled when thermal and other loads are applied
the loads and moments imposed on machinery and vessels by the thermal growth of the
attached piping are not excessive

Gives the input for

Input to civil for Structure design

And loads and displacement for support design and for hanger design.

Thank You