TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE.M6-ME-590-430 FLEXIBILITY & WEIGHT ANALYSIS FOR SHEET i OF iii

PIPING SYSTEMS

DESIGN GUIDE FOR CARRYING OUT

FLEXIBILITY AND WEIGHT ANALYSIS FOR

PIPING SYSTEMS

FILE NAME : M6ME430R2.DOC

REV.NO. R0 R1 R2 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY VS Sd/- RVS Sd/- PS

CKD.BY DP Sd/- VS Sd/- VS R2

APP.BY MSK/KG Sd/-/Sd/- MLN/RL Sd/-/Sd/- DVL/RL

DATE 30.07.1993 30.10.1999 25.10.2002

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TCE.M6-ME-590-430 FLEXIBILITY & WEIGHT ANALYSIS FOR SHEET ii OF iii
PIPING SYSTEMS

CONTENTS

SL.NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 FLEXIBILITY ANALYSIS 1

3.0 WEIGHT ANALYSIS 4

4.0 ANALYSIS OF LINES WITH

EXPANSION JOINTS 5

5.0 LIBERAL ALLOWABLE STRESS

FOR FLEXIBILITY 5

APPENDICES

1. DESIGN DATA AND RESULTS 7

OF FLEXIBILITY ANALYSIS

2. DESIGN DATA FOR WEIGHT 11

ANALYSIS

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REVISION STATUS

REV.NO. DATE DESCRIPTION

R0 30.07.1993 ----

R1 30.10.1999 Document completely revised.

R2 25.10.2002 Document Generally Revised

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1.0 SCOPE

This document describes procedure to be followed while carrying out flexibility

and weight analysis for power plant piping systems and also gives certain guide
lines for carrying out the above analysis. This guide does not cover any
considerations of seismic and fluid dynamic analyses.

2.0 FLEXIBILITY ANALYSIS

2.1 LINES TO BE ANALYSED

Formal flexibility analysis calculations shall be carried out in case of piping

subjected to restrained thermal expansion and contraction. Following piping
systems shall be analysed.

(a) Piping with a design temperature of 65 deg.C and above.

(b) If a piping system meets the following design criteria, then no formal
analysis is required.

DY
----- < = 0.03 (208.3)
2
(L-U)

where

D = outside diameter of pipe in inches (mm)

Y = Resultant of movement to be absorbed by pipe line

inches (mm)

L = Developed length of line axis, ft (m)

U = Anchor Distance (Length of straight line joining anchors)

ft(m)

Note : The above formula is applicable for piping systems having uniform size
with not more than two anchors and no intermediate restraints and
designed for non-cyclic service (Less than 7000 total cycles).

(c) Regardless of design temperature, all piping connected to sensitive

rotating equipment such as turbines, feed pumps, etc. for which limiting
value of pipe reactions are specified by the equipment manufacturer.

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2.2 OBJECTIVES OF FLEXIBILITY ANALYSIS

The flexibility analysis calculations carried out shall meet the following basic
objectives:

(a) To ensure that the stresses in the piping system are within the
permissible values as given in the applicable codes under operating
conditions.

(b) To ensure that the forces and moments exerted by the piping on
connected equipment are within the maximum allowable values
stipulated by the supplier of equipment under operating conditions.

(c) To obtain movements of the pipe at various points in the piping system
and consequently to check the interference of the pipe with other pipes,
equipment and structures.

(d) To obtain the vertical movement at hanger/support points for selecting

the type of hanger/support.

(e) To decide requirements of expansion joints, if it is not feasible to provide

natural flexibility.

2.3 DESIGN CODES

2.3.1 Flexibility analysis can be carried out as per following codes for power piping :

(a) ASME B 31.1

(b) BS 806

2.3.2 Unless specifically called for, ASME B 31.1 shall be used for Indian Projects.

2.4 PIPING LAYOUT AND ISOMETRIC

To start with, the piping layout shall be finalised based on flow diagram, general
arrangement and composite drawings. Upon completion of this, isometric layout
shall be prepared. To the extent possible, the location of hangers shall be
indicated on the isometric drawing and these shall be included as junction points
while preparing coding for carrying out the analysis. Generally cold springing
shall be avoided.

However, if cold springing is to be given refer design guide No.TCE.M6-ME-590-

408 - (Design guide for cold springing) for further details

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2.5 DISPLACEMENT AND ALLOWABLE LOADS ON EQUIPMENT

Obtain displacements and the allowable forces and moments at the equipment
terminal points. To the extent possible, the actual values shall be lower than the
allowable values specified by the equipment supplier. If there are marginal
deviation in the calculated loads from the allowable loads, consult the equipment
manufacturer for acceptance.

2.6 DESIGN DATA

2.6.1 Reference temperature while calculating the values of EC (modulus of elasticity

in cold conditions) and e (thermal expansion mm/metre) shall be 21 deg.C.

2.6.2 Follow the respective codes for calculating the EH, EC and e values, for
example:

BS 806 - For materials as per British Standards

ASME B 31.1 - For materials as per American Standards.

2.6.3 Complete all the data in Appendix 1 (Page Nos. sh. 7 to 9) before carrying out
the analysis.

2.6.4 Generally, the piping systems are analysed with nominal thickness and nominal
outside diameter (this is based on BS-806 & ASME B31-1). However, some of
equipment suppliers like Siemens (kWU turbine) require that the forces and
moments be calculated with all positive tolerances. In such a case consider the
above tolerances.

2.6.5 Different operating conditions shall be determined based on the heat balance
diagrams or the operating logic. Based on this complete the Appendix 1 and
identify different operating modes for carrying out the analysis.

2.6.6 After completing the weight analysis and based on the thermal movements of the
flexibility analysis select the spring constant. Refer design guide No.TCE.M6-
ME-590-410 - Selection of hangers in this regard. Input the spring constants in
the flexibility analysis. The spring constant need not be inputted for low pressure
piping systems. Tabulate the restraint data in Appendix 1.

2.7 Following sequence shall be adopted for carrying out the flexibility analysis.

(a) Carry out preliminary analysis (based on previous project experience,

tentative location of restraints).

(b) Locate the hangers based on design guide TCE.M6-ME-590-405.

(c) Select the hanger based on design guide No.TCE.M6-ME-590-410.

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(e) Optimise location of restraints and guides.

(f) Ensure that the pipes do not lift from the supports in any of the operting
conditions.

(g) Consider appropriate coeffcient of friction for the supports (0.3 between
steel to steel and 0.1 between teflon to steel).

(h) Take final outputs of flexibility and weight analysis

2.8 RESULTS

Use sheet 9 of Appendix1 for flexibility and sheet 14 of Appendix-2 for dead
weight for presentation of results.

3.0 WEIGHT ANALYSIS

This calculation is carried out for most of the lines with temperatures greater
than 65 deg.C. and where it is necessary to carryout formal flexibility analysis.
Generally this is not calculated for LP piping systems such as water, ash, fuel oil
and lube oil lines for which supports are designed by LP piping contractor.

3.1 UNIT WEIGHT CALCULATIONS

Unit weight calculations consist of the following components.

(a) Live load Live load consists of the weight of the fluid transported. Snow
and ice loads shall be considered in localities where such conditions
exist.

(b) Dead load The dead load consists of the weight of the piping
components, insulation, finishing cement and other superimposed
permanent loads.

(c) Test or cleaning fluid load (For gas / Vapour lines) this consists of the
weight of the test or cleaning fluid. This is not used for the selection of
spring hanger. However, hanger components shall be designed for this
load.

Complete details as indicated in Appendix-2 for calculating the weight / metre of

piping. This shall be completed in all respects before carrying out the weight
analysis on computer. If calculations are carried out manually use the design
guide TCE.M6-ME-590-415 (Hanger load calculations by manual method).

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3.2 COMPONENT AND OTHER WEIGHTS

3.2.1 Component weights and end to end dimensions shall be taken from the
catalogue or manufacturers drawing. Suitable weight for insulation and contents
shall be added in arriving equivalent weight per unit length.

3.3.2 Valve weights shall include the motor actuator weights if motor operated.
Suitable factor shall be provided for the insulation weights as well of weight of
contents.

3.3 SUPPORT REACTIONS

The support reactions for the weight analysis shall be obtained by using infinite
stiffness at all hangers / restraint points.

4.0 ANALYSIS FOR LINES WITH EXPANSION JOINTS

4.1 The pipe lines with positive pressures shall use the expansion joints with a finite
transverse stiffness & infinite axial stiffness. The expansion joints with finite axial
stiffness has tendency to open out under pressure and hence this precaution.
However, if a expansion joint with a finite axial stiffness is required the same shall
be anchored on either ends.

4.2 The modelling of the piping shall be done with the stiffness of the expansion
joints obtained from manufactures.

5.0 LIBERAL ALLOWANCE STRESS FOR ELEXIBILITY

The equation for thermal expansion as per ASME B31.1

SE = iMc < SA + f (Sh SL)

Z
Where

MC = The range of resultant moments due to thermal expansion.

f = Stress range reduction factors.

SL = Sum of longitudinal stresses due to pressure, weight and other sustained

loads.

Sh = Basic material allowable stress at the hot temperature.

This equation implies that the allowable stress range for temperature uses the
difference between the allowable stress for the sustained condition and the
actual stress in the sustained condition. Hence flexibility analysis shall always to
carried out in conjunction with dead weight analysis. The basic allowable stress
range SA can be used initially to establish flexibility of the piping as a conservative
measure.
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APPENDIX 1

DESIGN DATA AND RESULTS OF FLEXIBILITY ANALYSIS

1.0 SYSTEM -

2.0 LINE NUMBERS -

3.0 FLOW DIAGRAM NO. -

4.0 REF. ISOMETRIC NO. -

5.0 DESIGN CODE -

6.0 COLD SPRINGING / RELAXATION -

7.0 REF. INSTALLATION TEMP. (DEG.C) -

8.0 DESIGN PRESSURE -

9.0 NOTES -

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APPENDIX 1 (CONTD)

10.0 DESIGN DATA

SL. LINE PIPE ALLOW- MOD. PIPE POSTI- PIPE OD PIPE POISTIVE WALL BEND
NO. NO. MAT- ABLE COLD OF OD VE INCLU- WALL TOL. ON THICK- RADIUS
ERI- STRESS ELAST. mm TOLER- SIVE OF THICK- WALL NESS UNLESS
AL (SC) Kg/cm2 Ehx106 ANCE ON TOL. mm NESS THICK- INCL. OF OTHER-WISE
Kg/cm2 PIPE mm NESS TOLER- MARKED ON
OD% mm ANCE ISOMETRIC
mm

11.0 ANCHORS LOCATION & THERMAL MOVEMENTS

INITIAL THERMAL
MOVEMENT (mm)
SL.NO. ANCHOR LOCATION X Y Z REFERENCE
JN.NO. DOCUMENT

12.0 THERMAL DATA

SL.N OPERATING LINE NO. TEMP. BASIS MOD.OF THERMAL ALLOW. HOT
O. MODE DEG.C ELAST.Eh X EXPAN- STRESS
10E06 SION Kg/cm2
Kg/cm2 RANGE
(mm/mtr)

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APPENDIX 1 (CONTD)

13.0 ACCEPTABLE CRITERIA

13.1 SPECIFIC ALLOWABLE VALUES FOR PIPE REACTIONS :

EQPT. NOZZLES (ANCHORS..) -

STRUCTURES (ANCHORS & RESTRAINTS) -

INTERMEDIATE ON LINE POINTS

(VALVES & SPECIALITIES) -

13.2 OTHER REQUIREMENTS (IF ANY) LIMITING PIPING REACTIONS:

13.3 LIMITATIONS ON PIPE MOVEMENTS (IF ANY):

13.4 ALLOWABLE STRESS RANGE (Kg/Cm2):

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APPENDIX 1 (CONTD)

14.0 RESTRAINTS DATA

SL.NO. JN. NO. RESTRAINT TYPE OF SPRING CONST.

NO. RESTRAINT (Kg./cm)

15.0 Forces and Moments at Equipment Terminals / Anchors and at Restraint

points

X Co-ordinate :
Y Co-ordinate :
Z Co-ordinate :

FORCE (KG.) MOMENT (KG.M)

SL.N EQPT. JN CONDITION Fx Fy Fz Mx My Mz
O. TERMINAL POINT
/ ANCHOR NO.

Maximum Stress range is at and is kg/cm2

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APPENDIX 2

DESIGN DATA FOR WEIGHT ANALYSIS

1.0 SYSTEM -

2.0 LINE NUMBERS -

3.0 REF. FLOW DIAGRAM NO. -

4.0 REF. ISOMETRIC NO. -

5.0 DESIGN CODE -

6.0 DESIGN BASIS -

7.0 DESIGN PRESSURE -

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APPENDIX 2 (CONTD)

SL.NO. DESCRIPTION UNITS PIPE SIZES

8.0 PROPERTIES

9.0 PIPE MATERIAL

10.0 PIPE WEIGHT

11.1 OUTSIDE DIA, mm

11.2 NOMINAL WALL THICKNESS, mm

11.3 MATERIAL DENSITY Kg/cu.m.

11.4 PIPE WT. /METRE Kg.

12.0 INSULATION WEIGHT

12.1 INSULATION MATL.

12.2 DENSITY OF INSULATION Kg/cu.m.

12.3 THK. OF INSULATION mm

12.4 PIPE OD WITH INSULATION mm

12.5 INSULATION WT/m Kg.

13.0 WT. OF INSULATION FINISH

13.1 DENSITY OF FINISH Kg/cu.m.

MATERIAL

13.2 THK. OF MATERIAL mm

13.3 PIPE OD INCLUDING FINISH mm

MATERIAL AND INSULATION

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13.4 WT. OF INSULATION FINISH PER Kg.

METRE

14.0 WT.OF CONTENTS (FOR LIQUID

ONLY)

14.1 OPERATING FLUID

142 DENSITY OF OPER.FLUID AT Kg/cu.m.

INSTALLATION TEMPERATURE

14.3 DENSITY OF OPER.FLUID AT Kg/cu.m.

OPER. TEMPERATURE

14.4 WT. OF CONTENTS BASED ON Kg.

INSTALLATION TEMPERA-TURE
/ MTR.

14.5 WT.OF CONT. BASED ON Kg.

OPERATING TEMPERATURE /
MTR.

15.0 WT. OF TEST FLUID

15.1 TEST FLUID

15.2 DENSITY OF TEST FLUID AT Kg/cu.m.

INSTALLATION TEMPERATURE

15.3 WT. OF TEST FLUID BASED ON Kg./m

INSTALLATION TEMPERATURE

16.0 TOTAL UNIT WEIGHT OF PIPE

LINE INCL. OF INSULATION,
FINISH & CONTENTS

16.1 OPER. CONDITION Kg/m

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APPENDIX 2 (CONTD)

16.2 TEST CONDITION Kg/m.

16.3 ANY OTHER AMBIENT Kg/m.

CONDITION

17.0 WEIGHT DATA FOR PIPE FITTINGS, FLANGES AND VALVES

Sl.No. Size NB Item SCH / Unit Source Wt. of Wt. of Total wt. Length of Equivalent
(mm) description THK Weight of unit insulation content Inclusive of fitting / weight /
(mm) Kg. weight & finish (Kg.) insulation valve unit length
(Kg) finish & (m) of fitting /
content Valve
(Kg.) Kg/m

18.0 Maximum stress obtained due to sustained

Load (weight analysis) (S W) - Kg/cm2

19.0 Acceptance Criteria

The sum of longitudinal stress (S L) due to pressure, weight shall

not exceed the allowable stress in hot condition :

SL + S W < Sh

Where S L = PDo / 4tn

P = Design Pressure (Kg/cm2)

Do = OD of pipe (mm)
tn = nominal thickness (mm)
Sh = Hot allowable stress (Kg/cm2)

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