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
