Best Practice 03 December 2020

SABP-L-006
Pipe Stress Analysis Review
Document Responsibility: Piping Standards Committee

Previous Revision: 31January 2010 Next Revision: 03 December 2030

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 SABP-L-006 Pipe Stress Analysis Review

Contents

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 SABP-L-006 Pipe Stress Analysis Review

Scope
1.1 The objective of this best practice is to provide a methodology for reviewing electronic
piping stress analysis reports, stress analysis that are generated by design
agencies/offices for Saudi Aramco new projects or existing piping modifications.

1.2 This best practice is governed by the definitions and mandatory requirements of the
applicable ASME B31 Code and SAES-L-120 “Piping Flexibility Analysis”.

1.3 This best practice is intended to be used by Saudi Aramco Engineers who are directly
involved in design review; mainly CSD, PMT and Operation Engineers.

Conflicts and Deviations

If there is a conflict between this Best Practice and any Mandatory Saudi Aramco Engineering
Requirements (MSAERs), the mandatory document shall take the precedence. Other conflicts
shall be addressed in writing to the EK&RD Coordinator.

References
All referenced specifications, standards, codes, drawings, and similar material are considered
part of this Best Practice to the extent specified applying latest revisions unless stated
otherwise.
Saudi Aramco References
SAES-A-112 Meteorological and Seismic Design Criteria
SAES-L-100 Applicable Codes & Standards for Pressure Piping Systems
SAES-L-120 Piping Flexibility Analysis
SAES-L-125 Safety Instruction Sheet for Piping and Pipelines
SAES-L-310 Design of Plant Piping
SAES-L-410 Design of Pipelines
SAEP-303 Engineering Reviews of Project Poposal and Detailed
Desing Documentation

Industry Codes and Standards

ASME B31.1 Power Piping

ASME B31.3 Process Piping
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbon
and Other Liquids
ASME B31.8 Gas Transmission and Distribution Piping Systems
Energy Institute Guidelines for the Avoidance of Vibration Induced Fatigue
Failures in Process Pipework.

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Terminology

Definitions
Design Agency: Also called “Designer”, it is the agency responsible for designing the
piping system. It could be the design Contractor, the Lump Sum Turn Key Contractor or
any in-house design organization of Saudi Aramco.

Design Conditions: All conditions (such as pressure, temperature, ambient conditions,

service, steam-out, etc.) that govern all or part of the design and selection of piping
components.

Stress Analysis Report: Document that comprises the input, output and results of a
piping flexibility software as detailed at SAES-L-120 (Appendix A) and as required by
SAEP-303, which shall be submitted as a project deliverable at the 90%DD eReview.

Required Documents and Data for the Review

SA Reviewer to make sure that the Design Agency has submitted to Company the piping
flexibility analysis report as detailed at SAES-L-120 (Appendix A), and delivered as per
applicable SAEP-303 eReview guidelines. Stress Analysis reports can be submitted for review
to CSD-Piping Group via Engineering Service Request via CRM.
To be able to conduct a thorough review of piping stress analysis report, the below documents
and data shall be provided by the Design Agency:
1) Safety Instruction Sheet (SIS) of each pipe.
2) Process and Instrumentation Diagram (P&ID) showing/highlighing all lines involved.
3) Piping isometric drawings.
4) Stress Isometrics as extracted from the speciliazed software model.
5) Electronic “Computational Piping Stress Analysis” input (native files).
6) Expansion Joints data sheets (if applicable).
7) Spring supports/hangers data sheets (if applicable).
8) Equipment nozzles allowable loads as per the manufacturer or Code (if applicable).
9) Piping supports drawings details including friction factor for sliding supports.
10) Table of the structure stiffness (N/mm) of each steel structural member used for suporting
the lines as resulted from the structural steel computirized model (if applicable).
11) Local stress calculation reports of trunions-to-header connections (if applicable).
12) Dynamic load calculation including external forces, such as: slug force/two-phase force
calculations (if applicable).
13) Static, and Dynamic output reports, including but not limitted to: displacements, forces,
momments, stresses, and natural frequencies results of the piping system.

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Review of the Design Basis

Before stating the review of the design calculations, review of the design basis documents shall
be completed to verify the accuracy of the design parameters that are used in the calculations, a
detailed check list can be found in Appendix A.

Safety Instruction Sheet (SIS)

Safety Instruction Sheet of each line shall be submitted as per applicable SAES-L-125. The SIS
shall be the basis for all the design parameters of the model; the SIS includes detailed
information on line designation table, piping data, operating and design conditions.

Piping Isometric Drawings

Piping isometric provides the actual piping layout, support type and locations, piping material
specification and information to the connected equipment.

6.3 Stress Isometric Drawings

Stress isometrics as printed out directly from the software’s piping model, are the isometric
drawings that show all equipment, node no., material specifications, pipe restraints and other
information that are required to perform the analysis utilizing stress analysis software.

Review Computer Stress Analysis Modeling

The quality of the calculation results depends mainly on the accuracy of the input file. All input
parameters are important. However, this best practice is highlighting the most critical item that the
reviewer needs to check/verify as minimum. These items are addressed in the check list
Appendix-A.

Note: If stress analysis software is not availbale at the SA Reviewer’s offices, then the Design
Agency shall avail access to the used stress analysis software and model for further
review.

Load Combinations

When reviewing the computer stress analysis modeling, it is important to verify if all the possible
operational scenarios are analyzed, this can result in several load combinations for the same
piping system, each load combination is at different operational conditions.

Example:

When there is two pumps, pump (1) and Pump (2), one is normally operating and one is a
stand-by, the following load conditions should be considered:

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Table 1 – Load Combinations

Pump 1 Pump 2
Load Condition 1 Running (Hot) Running (Hot)
Load Condition 2 Running (Hot) Stand By (Cold)
Load Condition 3 Stand By (Cold) Stand By (Cold)

Similarly, if there is three pumps Pump (1), (2) & (3), two are operating and one is stand by, the
following load conditions should be considered:

Table 2 – Load Case Combinations

Pump 1 Pump 2 Pump 3

Load Condition 1 Running (Hot) Running (Hot) Running (Hot)
Load Condition 2 Running (Hot) Running (Hot) Stand By (Cold)
Load Condition 3 Running (Hot) Stand By (Cold) Running (Hot)
Load Condition 4 Stand By (Cold) Running (Hot) Running (Hot)

Review Calculation Results

Review that the calculated stresses, and displacements are within allowable by the applicable
ASME B31 Code, and to make sure that the loads and moments over-imposed by the piping
system, on its different load cases, are within the allowable of the equipment’s nozzles (as
applicable).

7.2.1 Review of the Report Stress Summary

Review that the ratios of actual stresses to the Code allowable stresses values are equal or
below 90%. Occasional loads such as: Hydrotest, Seismic, Wind, and Steam-Out cases are
acceptable to reach 100% as maximum.

Commentary Note:

ASME B31 Code allow to go till the 100% of the allowable stress on all load cases,
however, experience has shown that the final as-built piping set-up at the facilities may
has considerable differerences from the original geometry, parameters and assumptions
made at the model issued for construction. Therefore, an additonal safety margin of 10%
should be considered.

7.2.2 Review of Piping System Natural Frequencies

Review that the natural frequencies of the piping system calculated by the model at dynamic
analyses are at least 4 Hertz (Hz), so-called “Medium” as defined by the Energy Institute (EI)
“Guidelines for the Avoidance of Vibration Induced Fatigue Failures in Process Pipework”.

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In case of the piping is connected to a reciprocating rotating equipment, then check that the
natural frequencies of the piping system have been detuned at least +/- 20% from the
mechanical excitation frequency of the machine.

7.2.3 Horizontal Displacements

At any point of the piping system, and for any load case combination, horizontal
displacement shall be within the limit per the design criteria. The following is a
recommended practice:
1) In process unit the maximum movement at each side of the loop should not
be more than 6 inch.
2) In offsite area, the maximum movement at each side of the loop should not
be more than 12 inch.
3) The guideline for the thermal movement at the corner when pipe changes
direction should be limited to a maximum of 6 inch in the process area and
10 inch in the offsite area.

7.2.4 Vertical Displacements

7.2.4.1 Review that Design Agency has ensured that all pipe supports will be
active during all load cases as per SAES-L-310 (13.2.2). Lift-Offs should
not be acceptable, unless further assessement is conducted.

Commentary Note:

Models where piping supports may be active in some conditions (resting

in its supports) and inactive in others (Lifted off from its supports) may
lead to potential fatigue due to cyclic loads, vibration issues, or even
potential problems related to the inadvertively installation of shims to fill
the gaps during operation which may lead to overstress when the pipe
come back to the previous operating case.

7.2.4.2 Review that axial thermal expansion on vertical stationary equipment

such as (columns, towers, etc) are considered, and, if supports are
provided from the vessel to the piping, then make sure that the Design
Agency has properly linked the piping to the vessel in the model by
utilizing connecting nodes (CNodes).

7.2.5 Equipment Nozzle Loads

The SA Reviewer shall verify that all Equipment nozzel loads are qualified per
the vendor’s allowable or per the applicable Code or standard or such as:

• NEMA SM23 Evaluates piping loads on steam turbine nozzles

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• API 610 Evaluates piping loads on centrifugal pumps

• API 617 Evaluates piping loads on centrifugal compressors
• API 618 Evaluates piping loads on reciprocating compressors
• API 661 Evaluates piping loads on air-cooled heat exchangers
• API 560 Evaluates piping loads on fired heaters
• WRC 107 Evaluates the vessel stresses in the immediate vicinity of a
nozzle
• WRC 297 Computes stresses in the nozzle in the vessel (evaluation of
stresses in cylinder-to-cylinder intersections)

7.2.6 Spring supports, spring hangers, and expansion joints

Displacment, forces, and loads of spring supports, spring hangers, expansion

joints per the manufacturer specifications.

7.2.7 Local stress analysis at Trunnions

Local stress analysis has to be conducted for pipe trunnions to ensure stresses
are withing allowable by using the added features of the flexibility analysis
software. Acceptable methods are: Kellog’s choking model (reference L. C. Peng
and T.L. Peng, Pipe Stress Engineering, ASME, New York, 2009) , or Finite Element Analyis
(FEA).

Post Construction Stress Verification

The Design Agency should verify that the piping is constructed per the stress isometric, and the
construction isometric, including but not limited to all the supports details (guide, axial stop, spring
support, gap, zero gap, sliding support, etc). This activity has to be conducted twice, first when the
construction and acceptance of the line is completed (before start-up), and the second check to
be performed just after the start-up with the line in service (once the pipe has moved from cold-
position to hot-position) as per attached Appendix B.

The Design Agency should re-run the stress analysis if any major discrepancy is observed, and
plan and execute for the required field corrections as applicable.

Document History

31 January 2010 First Issuance

03 December 2020 Major Revision - Incorporated requirements for Natural Frequencies checking and
updated requirements as per SAES-L-120.

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Appendix A – Pipe Stress Analysis Check List

Reviewer’s Name:

Calculation No. Including BI No.

Review Date:
Document
Item Description of item Comments
Title
1 SIS Is the code used in compliance with SAES-L-100?
2 SIS Is the wall thickness calculation utilizing the applicable code?
3 SIS Is the hydrotest pressure calculation per SAES-L-150?
SIS Is the design temperature vs. Material allowable based on the
4
ASTM and the applicable code?
Piping Does the piping and fittings material specification match the
5
Isometrics information on the SIS?
Piping Does the Piping Iso. Include all valves/equipment that are shown
6
Isometrics on the P&ID for that line?
Stress
7 Does the stress Iso match the routings of the piping isometric?
Isometric
Stress Does the stress Isometric drawing include node numbering for
8
Isometric computer stress analysis modeling?
Stress Does the stress Isometric drawing include dimensions per the
9
Isometric piping isometric?
Stress Does the stress Isometric drawing include material
10
Isometric specifications?
Stress Does the stress Isometric drawing include insulation type and
11
Isometric thickness?
Stress Does the stress Isometric drawing include details, type and
12
Isometric locations of the restraints?
Modeling Are all equipment nozzles are identified as anchors with the
13
equipment’s thermal expansion?
Modeling Are all pipe supports and restraints are modeled per the stress
14
isometric?
15 Modeling Is all pipe support friction factor as per SAES-L-120?
Modeling Is the thermal expansion of the equipment considered in the
16
modeling?
Modeling Is the analysis being terminated (stress analysis boundary) at an
17
anchor or at least at a three way restraint?
Modeling Are the spring supports modeled correctly (variable, constant,
18
preloading, spring rate….) ?
Modeling Are the expansion joints modeled correctly (type, spring rates,
19
displacements…)?
Are all fittings such elbows, tees, branches,… modeled with the
applicable SIF “stress intensification factors”? And if the
20 Modeling
analysis uses SIF other than those in the applicable code,
supporting calculation shall be included.
21 Modeling Does the code that is used match the SIS data
22 Modeling Is the design pressure that is used match the SIS data?

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23 Modeling Is the design Temperature that is used matching the SIS data?
24 Modeling Was wind load condition considered in the Model?
25 Modeling Was Seismic load condition considered in the Model?
Do the load combinations represent all the possible scenarios of
26 Modeling operations (design condition, operating condition, hydrotest
condition)? See Paragraph 6.1
If the system will be subjected to steam out, was the steam out
27 Modeling
considered as a load condition?
Is the modeling of the supports connected to the equipments
28 Modeling (Pressure Vessels, tanks…) per the computer Stress analysis
technique ?
29 Modeling Are the Differential settlements considered in the modeling?
30 Modeling Are the units consistent that are used in the model?
31 Modeling Is the model considering flexible nozzles?
Did the model utilize the program database for material
32 Modeling
specifications?
33 Modeling Is the Fluid density used corresponds to the service?
Are the weights of components such as valves, flanges, … etc
34 Modeling
including bolts inputted correctly?
Calculation Are the Maximum stresses for all cases including the combined
35
Results stress meet the code allowable?
Calculation Is the line continuously resting at its supports during all the load
36
Results cases?
Are the Maximum horizontal displacements at any point for any
Calculation
37 load combination within the limit per the design criteria? See
Results
Paragraph 6.2.1
Are all Equipment nozzle loads qualified per the applicable code
Calculation
38 or standard or with-in the vendor’s allowable? See Paragraph
Results
6.2.2
Calculation
39 Are the Spring hanger reports match the spring data sheets?
Results
Calculation Are the Expansion Joints displacements and stresses match
40
Results Expansion Joint data sheets?
Flange checking has been performed as required per SAES-L-
41 Modeling
120?
Check that external forces provoked by dynamic loads, such as:
42 Modeling Slug Flow, are calculated as per SAES-L-310 (13.10.4) and input
at elbows (as applicable).
Are reaction forces applied at the elbows of relief valve
43 Modeling
discharge piping?
Are the deflections/reactions of the steel structure considered in
44 Modeling
the piping model?
Are the stiffness of the steel structure members (if applicable)
45 Modelling
input at the model?
46 Modeling Is the weight of cement internal coating considered in the model?
47 Modeling Confirm that cold spring has not been applied in the spools.
In case of Tie-in to and existing piping; is the existing line
48 Modeling
analyzed considering the over-imposed loads of the new piping?

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Appendix B– Pre Start-Up and Start-Up

Final Piping Stress Check Out

Design Agency Representative Name: Review Date:

Project: BI #:

Location:
Plant/Facilities:
Pre Start-Up Post Start-Up
Item Description of item
Check Check
Confirm that the piping system was constructed as per the latest
1 Issued-For-Construction (IFC) Isometric drawings?, Please
record the revision number at right column.
Supports were constructed as per the latest support drawings?,
2
Please record the revision number at right column
Confirm that the transportation stoppers of the spring supports
3
are removed after hydrostatic test? Y/N
Are the spring supports calibrated and set at the correct cold-
4
load (Pre-Start-Up) or hot-load (Post Start-Up)? Y/N
If the line is marked on P&IDs as Two-Phase or Slug Flow
5
then check for mandatory anchor supports. Y/N
If U-bolts are installed then confirm whether or not are anchor
6
type or guide type as per stress isometrics. Y/N
Are guides, stoppers, anchors and spring supports located as per
7
stress isometrics? Y/N
Confirm gaps at supports were provided as per stress
8 isometrics, and confirm gap measurement accordingly.
Make sure that the marked as “gaps=zero” were observed. Y/N
Are sliding shims or plates (if required) firmly attached to the
9
support/structure? Y/N
Is there any vibration or abnormal movement perceived at the
10 line or its supports? Y/N. If “YES” report it to Design Agency
Stress Department for proper assessment and recommendation.
Confirm that there is not clashing with structure or other
11 elements and meeting the minimum distances as per SAES-L-
310 and SAES-L-410 as applicable. Y/N
Confirm that the line is actively resting in its supports and that
12 there is not lift-off (air gap) between the line and its supports.
Y/N
Confirm that the line was not cold-spring, to meet its position.
13
Y/N
Confirm the line is not over imposed excessive load or
14 momentum at equipment nozzle, particularly pumps, turbines
and compressors.
Confirm that there is not abnormal bending, sagging, buckling
15
or snaking of the line.

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