OUTLINE OF GUIDELINES

FOR
PIPE SUPPORT ANALYSIS

ANUGUL 01 21-Nov-2016 Issued for

Design
Checked Approved Prepared Rev Date Description
 Table of Contents

1. Objective 3
2. References 3
3. Terminology 3
4. Scope 3
5. Procedural Outline 3
6. Guidelines for non-Structural teams
6.1 Strategy

a) Stress Analysis 4
b) Pipe support Analysis- Level 1, Standard supports 5
c) Pipe support Analysis- Level 2, Special supports 6
6.2 Documentation 10
7. Guidelines for Structural teams
7.1 Strategy 11
7.2 Documentation 15
8. Delivery 16

List of Figures:

Fig 1: Propped Cantilever-Type Pipe Support 4

Fig 2: Extract from NCIC-FCS-1G000-ESS-SPC-0002-SUPPORT DESIGN BASIS 6
Fig 3: Extract from NCIC-FCS-1G000-ESS-SPC-0002-SUPPORT DESIGN BASIS 7
Fig 4: Sample pipe support extracted from PDMS and loads mentioned 7
Fig 5 : Fixed-end, ‘L’ shaped support 8
Fig 6: Grouping strategy for similar supports 9
Fig 7: Grouping strategy for dissimilar supports 10
Fig 8: Dummy element modeling in STAAD 11
Fig 9: Locating special supports in Navisworks 13
Fig 10: Support with small changes: (changes in Red) 13
Fig 11: Support with Major changes: (Rendered from STAAD) 14

List of Tables:

Table 1: Example of CEASER Stress analysis result 5

Table 2: Maximum load values and sections for pipe supports of type - Fixed-end
‘L’ shaped support 8
Table 3: Sample tracker contents 10
Table 4: Load Combinations for Pipe support analysis 12

Appendices
Appendix 1: Standardization with HEB Sections
Appendix 2: Support Types

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1 Objective

This document outlines and explains the life cycle of pipe supports - analysis, design and
documentation.

2 References

- Standardizations for HEB Sections – see Appendix 1

- Stress Design Basis -Sample, NCIC-FCS-1G000-ESS-SPC-0001
- Support Design Basis -Sample, NCIC-FCS-1G000-ESS-SPC-0002

Please see additional references in respective sections.

3 Terminology

CEASER II – Stress analysis software used by stress team

STAAD Pro – structural analysis Software
PDMS – Complete project with all systems rendered in 3-d that is modifiable, extractable
Navisworks -3D model of project that is updated at day end as a PDMS output of all updating
WRENCH - Document management and timesheet recording software
MTO - Material take-off
Standard/Primary supports Pipe supports that follow Outotec standards
Secondary supports - require additional framing or members to support
Special Supports – Supports that fall outside of structural standardizations

4 Scope

The detailed scope and responsibilities of each department are to be clarified at the outset of each
project. e.g., Trimmer inclusion in the model by a specific department.

5 Procedural outline

 Pipelines are analyzed with CEASER II software by stress analysis team. Different
combinations are considered to arrive at maximum loads in 3-dimensional coordinate
system.

 Once loads are given, piping team assigns a pipe support shape to support the pipe, based on
dimensions, other pipelines being supported nearby, shoe size, loads, supporting beams.
For example, in presence of large horizontal loads, a brace is assigned.

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 Fig 1: Propped Cantilever-Type Pipe Support

 Piping team extracts the pipe support view from PDMS. Loads are written down and given to
structural department.
There are two standardization criteria:
1. Given by Outotec. Piping team designs accordingly. Remaining supports go through
another set of standards, developed by structural team.
2. Structural team

 Pipe supports are standardized by the structural analysis team, based on:
- Shape
- Span
- Sections used
- Load

This is an optimization activity. It is elaborated in Section 7 and Appendices.

 For the pipe supports falling under the standardizations (see above), the support is sent directly
for further design. Those supports that fall outside the geometry, load, pipe size criteria, are
called special pipe supports and are given for further individual analysis.

6 Guidelines for non-Structural teams

6.1 Strategy

a) Stress Analysis

 Minimum requirements for piping flexibility and stress analysis are provided in the stress design
basis. Technical accuracy of the pipe support system primarily rests with the stress team. They
provide with loads, moments and displacements, as necessary.

 References and study, includes the following documents, but is not limited to:
- Stress Design basis for the project
- API codes for pumps, turbines, compressors specific to the petroleum, chemical and Gas
industries

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 - ASME codes for pipe flanges, fittings, large diameter steel flanges, power and process
piping, fluid transmission and distribution systems
- WRC publications
- ISO specifications for centrifugal pumps
- NEMA standards
- BS codes
- Any other local codes, as applicable or mentioned in general design basis

 Presently loads are given at base of shoe for higher diameter pipelines. It is to be clarified with
the stress team as to how loads are to be read.

 Earthquake loads must always be considered in downward direction, as they yield maximum
stress values and hence larger pipe loads. Friction must be appropriately applied to account for
different linings of pipes, types of fluid that flow through. Safety factors at bends, branches are
also to be accounted for.

 There might not be one combination to yield maximum loads in each direction. Individual
maximum loads in each direction are generally given for analyzing the structural support
required. In exceptional cases, the structural support is individually analyzed for each
combination in respective directions.

Table 1: Example of CEASER Stress analysis result

Node # Load Comb # FX (kN) FY (kN) FZ(kN)

1 2 5 10
2 1 6 8
3902
3 5 2 4
Final 5 6 10

In Table 1, each load combination has a maximum load in one direction only. The loads to be
considered would be as shown in last row (Final) of table 1, maximum of all three load
combinations. In a few cases, all the three load combinations might have to be individually
tested to optimize design. This is not practiced for all supports keeping optimization in view.

b) Pipe support Analysis- Level 1, Standard supports

 Support Design Basis, e.g., NCIC-FCS-1G000-ESS-SPC-0002 is to be diligently followed.

This gives an idea of what type of shoe is to be placed, how different types of pipes are
to be supported, how to model simple supports, span limitations, where to place
different kinds of supports-axial stops, hangers, etc.

 Further references and study, includes the following documents, but is not limited to:
- Standard pipe support Drawings
- Pipe stress specification
- Piping material specification
- Painting procedure specification

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 - ASME codes for power and process piping
- MSS standards for material design of pipe hangers and supports
- MSS standards for selection and application of pipe hangers and supports

As shown in Fig 2., Outotec’ s support design basis contains details on designing spans, guide
spacing, support type to be selected, etc.

For example, for a 1” vertical pipe that falls under STD schedule, supports need to be provided
every 4.2 m, with a guide space of 6 m.

Fig 2: Extract from NCIC-FCS-1G000-ESS-SPC-0002-SUPPORT DESIGN BASIS

c) Pipe support Analysis- Level 2, Special supports

 Pipe supports falling out of the standard norm- by Outotec or structural team, are to be
classified as special supports. Fig 3 is an excerpt from support design basis from Outotec-

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 NCIC project, indicating the type of supports that are to be sent for further structural
analysis.

Fig 3: Extract from NCIC-FCS-1G000-ESS-SPC-0002-SUPPORT DESIGN BASIS

 Each special pipe support is extracted from PDMS consisting of four views. Please see Fig 4.
- North (negative north / south could also be shown)
- East (negative east / west could also be shown)
- ISO (isometric) View
- Elevation/Top View

Fig 4: Sample pipe support extracted from PDMS and loads mentioned

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 Support data sheet also would contain project data, section cut-lengths and weight.

 Support number can be read from the bottom right box. For example, in Fig 4., SU10492 (in
red, in Fig 4) is the pipe support number. The node number is checked against the stress
team list for loads. Loads are written down (in blue, in fig 4).

 Structural standards are explained as follows - In Fig 5, a fixed-end, ‘L’ shaped support is
illustrated. In Table 2, the range for operable L, H for maximum lateral and vertical loads is
given. The tabulation can be done for various parametric studies, but practically used spans
are assumed and load carrying capacity is estimated.

Fig 5 : Fixed-end, ‘L’ shaped support

Table 2: Maximum load values and sections for pipe supports of type - Fixed-end, ‘L’
shaped support

Max Pipe Max Vertical Max Lateral MEMBER MEMBER

Size Load, FV (kN) Load, FL (kN) A B H (mm) X (mm)
4" 7.8 1.1 UPN 80 UPN 80 1200 1200
8" 11 1.5 UPN 100 UPN 100 1200 1200
12" 37 5.5 HEB 100 HEB 100 1500 1500
16" 54 6.5 HEB 120 HEB 120 2000 2000

The first row in above table could be read as, for pipes up to and less than 4 inches, for a
maximum dimensional constraint of vertical height, H of 1200mm and up to a horizontal
length of 1200 mm with total Vertical load capacity would be 7.8 kN and a total maximum
lateral load of 1.1 kN - using a UPN80 section would be optimal.

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 Examples:

a) If a 4” pipe was to be supported with a vertical load of 10 kN as obtained from CEASER

software, with H and L of 1000mm, then a UPN100 should be selected to support this
type of arrangement.
b) If an 8” pipe was to support a vertical load of 2 kN and a lateral load of 6 kN with spans of
1500mm both vertically and horizontally, then a HEB 120 section should be selected.
Lateral load fits row 4 more than row 2 and row 3.
c) If three 2” pipes with a combined vertical load of 6 kN and combined horizontal load of 1
kN, with spans (L and H) of 1100 mm, then row 1 is a choice, with UPN 80 for member A
and member B. No need to choose UPN 100.

 Piping team can assign secondary supports for most of the non-standard supports. The ones
that fall outside level 2, would be handed over to the structural department with loads, for
further analysis.

 Group similar supports and send one support for further analysis. This grouping can be done
for loads, shoe type, support type and geometry within 20% of each other.

Examples:

a) In Fig 6, geometrically and support condition-wise S#1, S#2 and S#3 are similar. Since
with similar shoe, stop conditions and loads for S#1 and S#2 are similar, they can be
grouped. S#3 is to be analyzed as a separate support as it requires a stronger section.

Fig 6: Grouping strategy for similar supports

b) In Fig 7, all supports are geometrically same. But because of different shoe, span and
internal pipe stress condition, loads are different. All of them cannot be grouped as we
might end up over designing some supports. S-5 has a small lateral load. So, S-1, S-2, S-5
can be grouped together. S-4 has 50 % higher lateral load than S-3. If both can be
covered by standardizations, S-3, S-4 can be designed by piping. If S-4 is not covered in

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 standardizations but S-3 is, then S-4 will be handed over to structural department for
separate analysis.

Fig 7: Grouping strategy for dissimilar supports

6.2 Documentation

 For standard supports, maintain an excel file with support number. This is also useful in
extracting weight MTO.
 Printout special supports, individually. Indicate loads for each pipe involved.
 Upon completion, apply check print seal, fill in respective cells.
 Maintain an excel file to track the special supports issued to the structural department (see
Table 3). This file must contain:
- Support number
- Date of issue to structural analysis team
- Date of analysis by structural team/date of return
- Date of implementation of changes suggested, if any
- Remarks
- Counter for total number of supports issued
- Counter for supports to be analyzed
- Counter for completed supports

Table 3: Sample tracker contents

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  After implementing any changes, use a backdraft check print seal to document. Green marker
over the changes implemented (initially suggested in red or blue ink by structural team or inter
departmental checker). Follow the order for documenting copies of a support:
- Self-check
- check print
- back draft check print seal (if changes are suggested in check print or support is reissued).
These may be as many as required to reflect changes.

7 Guidelines for Structural teams

7.1 Strategy

 For analyzing pipe supports required input would be

- Materials
- list of sections usable
- bolt and plate sizes
- weld sizes
- support conditions
 fixed if welded
 fixed or pinned if bolted
- dummy modeling
 if loads are given at base of shoe, no need to model a dummy
element
 if loads are given at center of pipe, then the distance between center
of pipe to center of supporting beam below shoe is to be modeled as
a dummy element, that doesn’t contribute to the stiffness of support
structure during analysis but gives the effect of loads being applied at
an eccentricity. Please see Fig 8 describing a dummy element, Fig 8
has the same support as seen in Navis.

Fig 8: Dummy element modeling in STAAD

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 - load contingencies
 5-10 % for self-weight, accounting for weld weight, bolt weight, etc.
 Special springs or hanger supports
- Load combinations. Eight Load combinations are usually used. Please refer Table 4 below.

Table 4: Load Combinations for Pipe support analysis

Load X Y Z
Combination DIRECTION DIRECTION DIRECTION

1 + + +
2 - + +
3 - - +
4 + - +
5 + - -
6 + + -
7 - + -
8 - - -

- Code for design

- Design parameters – LX, LY
- stress limits (OVR-overstress limits for extreme events that uses extreme yield strength
capacity for short duration of load)
- acceptable UC ratios (actual stress to allowable stress ratio, which always should be a max
of 1, sometimes reduced to 0.9 based on accuracy of load estimation)
- allowable deflection limits

 Following documents are to be referred:

- Support Design basis
- Structural design basis
- Standardization References - Appendix 1
- Pipe support types -Appendix 2

 In Navis, the supports are located with the help of support number. ISO view corresponds to
left-front view in Navis, as shown, in Fig 9.

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 Fig 9: Locating special supports in Navisworks

 These supports are modelled in say STAAD.pro and recommendations (see Fig 10) are sent to
design team. Sometimes, rendered views (see Fig 11) in STAAD are attached for better
understanding. It is elaborated in further sections as to how to document modifications,
suggestions.

Fig 10: Support with small changes: (changes in Red)

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 Fig 11: Support with Major changes: (Rendered from STAAD)

 Staad Modeling directives:

- Axis orientation – in CEASER and Navis, Z is up while in STAAD, Y is upwards. Apply load
accordingly to axes. Flip Y and Z loads for STAAD usage or as necessary

- Any special supports sharing beams or close by, are to be all modelled together. Fig 11 is a
good reference how multiple supports are modeled together

- Say, a support#1 is exceeding in deflection and connecting to support#2 reduces the

deflection to acceptable limits, then the support#2 also needs to be modeled along with said
support

- It is always an objective to achieve maximum utility of sections.

 different orientations of member are also to be explored
 smaller or lighter sections could be considered

- Any solution must ponder any obstructions in Navis

- Minimize providing additional secondary / trimmer beams
- Provide stiffeners on supporting members, where:
 reactions are large at support points
 local flange buckling is a possibility
 heavy equipment is connected
 there is no supporting beam on either sides and a load might cause local torsion
 high torsion is expected

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  smaller secondary beams with pipe supports of significant pipe loads are connected
to existing structure
 pipe shoes transmit high loads to supporting members
 web is perpendicular web and shared contact area of supporting beam is less (need
both front and back stiffeners in this case)

- If piping team doesn’t provide hard copies of supports, then loads provided by stress team per
node would be read (compared against support number and node list) and analyzed

7.2 Documentation

- Mandatory changes are those, without which the pipe cannot be structurally supported and
or the supporting members are not deemed structurally safe either by strength or
serviceability limits of assigned code provisions. Clearly indicate any mandatory changes in
red ink, on the pipe support sheet
 Increase in section size
 Change in section orientation
 Addition of members-braces, tie beams
 Stiffeners location
 Base plates where pipe support member size is slightly larger than supporting beam
of main structure (supporting beam should be structurally safe for the reaction
though)
 Bolt numbers, sizes, if required by scope of work
 Weld thickness, if required by scope of work
 Support reactions where required, say equipment clips, if required by scope of work
 Any other information vendor might require

- In some cases, other departments need to conform to internal standards (clearances, shoe
sizes and hence the supporting members) and implementing all suggestions is not possible.

- Write notes in blue, when it is not mandatory to implement changes, but implementing
would:
 Reduce Structural weight
 Reduce fitting costs
 Improve access
 Resolve clashes
 Reduce associated work of analysis or drafting

- Update “Issued by Structures” column in Table 3, once the support analysis is complete

- Upon completion, apply check print seal, fill in respective cells. If supports are reissued with
different loads, then back draft check print seal would be used instead of check print seal

- Address any doubtful areas with client or vendor, like requirement for connection details,
change of sections to clip, support reactions, etc.

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 - Any changes to design basis regarding deflection limits or variation in changes must all be
communicated with client and documented

- Before delivery, scan the pipe supports and archive for convenience of future reference

8 Delivery

 Drawings are sent via WRENCH software

 STAAD files are stored on server and can be referred as required. They will be sent when
required by client
 MTO (Material take off) for all pipe supports would be also sent, by section size. This
must also include any joint design details like bolts, etc., depending on design basis
 Any changes from vendor or client will be duly reflected in analysis and further revisions
are sent after appropriately documenting
 Timesheets must be booked as per project code

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APPENDIX 1 - STANDARDIZATION FOR HEB SECTIONS

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H, L are in mm, FV and FL are in KN, NPS – nominal pipe size

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APPENDIX 2 - SUPPORT TYPES

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