B31.3 Process Piping Course - 06 - FlexibilityAnalysis

ASME B31.3 Process Piping Course 6.
Flexibility Analysis
ASME B31.3 Process Piping
Charles Becht IV, PhD, PE

Don Frikken, PE
Instructors
BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 1
Piping Development Process

1. Establish applicable system standard(s)
2. Establish design conditions
3. Make overall piping material decisions
Pressure Class
Reliability
Materials of construction
4. Fine tune piping material decisions
Materials
Determine wall thicknesses
Valves
5. Establish preliminary piping system layout & support
configuration
6. Perform flexibility analysis
7. Finalize layout and bill of materials
8. Fabricate and install
9. Examine and test
ASME B31.3 Process Piping Course 6. Flexibility Analysis
6. Flexibility Analysis
¾ What are we trying to achieve?
¾ Sustained loads
Cause primary stresses
Failure modes
Design criteria
¾ Displacement Loads
Cause secondary stresses
Failure modes
Design criteria
¾ Reaction design criteria
¾ Flexibility Analysis Example
The Material in This Section is

Addressed by B31.3 in:
Chapter II - Design

What are we trying to achieve?

1. Provide adequate support;
2. Provide sufficient flexibility; and
3. Prevent the piping from exerting

excessive reactions

1. Provide adequate support to resist loads
such as pressure, weight, earthquake
and wind
January 17 1994 Northridge Earthquake


2. Provide sufficient flexibility to safely
accommodate changes in length resulting
from temperature variations

3. Provide sufficient support and flexibility to
prevent the piping from exerting
excessive reactions on equipment and
restraints


And we do that in order to
make the piping look well supported to the
facility engineers and operators
prevent collapse of the piping
prevent leaks due to fatigue cracks
prevent joint leakage caused by excessive
forces , and
prevent failure or malfunction of attached
equipment caused by excessive reactions
Sustained Loads
¾ Imposed mechanical loads that are essentially
unchanged by the displacement that the loads
produce and cause primary stresses
¾ Governed by equilibrium – load controlled
¾ Examples:
Circumferential stresses (pressure)
Longitudinal stresses (pressure)
(weight)
(earthquake)
(wind)

Sustained Loads - Weight
Deformation
Load
Sustained Loads
σ1
Load controlled (primary)

Stress (load)
Strain (deformation)
Sustained Design Criteria

The sum of the longitudinal stresses due to
pressure, weight, and other sustained loadings, SL,
must not exceed the hot allowable stress, Sh, times
the weld joint strength reduction factor, W.
SL ≤ ShW
In the absence of more applicable data, W shall be

1.00 for all materials 950ºF (510ºC) and below
0.50 for all materials at 1500ºF (815ºC)
Linearly interpolated for intermediate temperatures

For Occasional loads such as wind and
earthquake
1. The sum of the longitudinal stresses due to
pressure, weight, other sustained loadings, and
stresses produced by occasional loads, SL,
must not exceed the hot allowable stress, 1.33
times Sh.
SL ≤ 1.33 Sh (Ec)
1.33 times Sh cannot exceed the yield strength of the
material at temperature


2. For temperatures above 800ºF (427ºC), the
sum of the longitudinal stresses due to
pressure, weight, other sustained loadings, and
stresses produced by occasional loads, SL,
must not exceed 90% of the yield strength at
temperature times a strength reduction factor.
SL ≤ 0.90 Syt X (Ec)
Where the strength reduction factor X = 1.0 for
austenitic stainless steels and 0.8 for other
materials
This alternative may not be used for cast irons or
other materials with non-ductile behavior.
Displacement Loads
¾ Actions that cause one end of a pipe
segment to move relative to the other end
and actions that have an equivalent effect
¾ Deformation controlled
¾ Examples:
Thermal expansion
Tank settlement
Rising and falling of docks
¾ Peak stresses are calculated using stress
intensification factors
Displacement Loads
Displacement 1
Displacement 2
Displacement Loads
σ1
Load controlled (primary)

Stress (load)
Deformation controlled (secondary)
Strain (displacement)
Displacement Loads
σ ≥ 2Sy
σ ≤ 2Sy
Displacement Loads
Displacement 1
Displacement 2
Displacement 1
Displacement 2

Displacement Design Criteria

¾ Acceptance criterion is based on the
stress range, usually
From the coldest condition (consider winter
shutdown ambient)
To the hottest condition (consider excursion
operation)
¾ The Code allowable stress range is based
on the twice yield stress criterion:
Stress Range ≤ 2 Syt

¾ It is anticipated that the piping will yield
during its initial cycles of operation
¾ The allowable stress range is established
in consideration of shake down to elastic
cycling


SA = f [1.25(Sc+Sh) - SL]
Where:
SA = allowable displacement stress range
f = stress range factor
Sc = basic allowable stress at minimum
temperature
Sh = basic allowable stress at maximum
temperature
SL = longitudinal stress

SA = f [1.25(Sc+Sh) - SL]
¾ In the case where Sc and Sh equal 2/3 Syt,
the quantity 1.25(Sc+Sh) will be equal to
1.67 Syt (≤ 2 Syt)
¾ In the case where Sc equals 2/3 Syt and
Sh equals 90% Syt, the quantity
1.25(Sc+Sh) will be equal to 1.96 Syt (≤ 2
Syt)


SA = f [1.25(Sc+Sh) - SL]
¾ In order to account for the range of
temperatures, the average of values at
the cold temperature and the hot
temperature are used

SA = f [1.25(Sc+Sh) - SL]
In order to assure that the stresses caused by
sustained loads are not additive to the
displacement stresses in such a way that
ratcheting would occur, SL is subtracted from
the allowable


SA = f [1.25(Sc+Sh) - SL]
Different approaches are used
SL is subtracted at each point in the system
The maximum SL for the system is subtracted
The allowable SL is subtracted

SA = f [1.25(Sc+Sh) - SL]
When the allowable SL is subtracted, the
equation becomes
SA = f (1.25Sc+ 0.25Sh)
This is sometimes called the “conservative”
allowable stress range.


SA = f [1.25(Sc+Sh) - SL]
¾ The stress range factor is introduced in
order to account for fatigue
f = 6.0 N-0.2 ≤ fm
¾ Where
N = equivalent number of full displacement
cycles
fm = 1.2 for ferrous materials with ST ≤ 75 ksi
(517 MPa) and T ≤ 700ºF (371ºC),
otherwise 1.0

1,000,000
Markl Fatigue Curve for
Buttwelded Steel Pipe.
Average
100,000
Stress Range
Fatigue
Failure
Design
Fatigue
10,000 Curve
Based on SA = 40,000 f Limited to
1.0
f Limited to
1,000 1.2
1 100 10000 1000000 10000000
Number of Cycles 0


SA = f [1.25(Sc+Sh) - SL]
f = 6.0 N-0.2 ≤ fm
¾ When f > 1.0, Sc and Sh shall be limited to
20 ksi (138 MPa)
¾ The minimum value for f is 0.15, for which
the pipe is considered suitable for an
unlimited number of cycles.


f = 6.0 N-0.2 ≤ fm
N = NE + Σ ri5Ni
Where
NE = Number of cycles for maximum displacement
Ni = Number of cycles for reduced displacement
ri = Ratio of stress range for reduced
displacement to stress range for maximum
displacement

N = NE + Σ ri5Ni
For NE = 1000 cycles at 30,000 psi stress range with
reduced displacement stress range cases as
follows.
Reduced No. of Stress
Case Cycles Range ri ri5Ni
1 7000 10,000 0.33 27
2 20000 6,000 0.20 6
N = 1000 + 27 + 6 = 1033.

Allowable Stress Range Workshop

What is SA for the styrene monomer piping
material specification described on page
50 of the supplement?
Assume the line is expected to be steam

cleaned with 50 psi (3.5 bar) steam
superheated to 735ºF (390ºC) 4 to 6 times
each year.
Reaction Design Criteria

The Code does not have any design criteria
for reactions. Most people use the following:
For equipment, most manufacturers will provide
allowable reactions
For supports, anchors and other restraints,
agreement on acceptable reactions is with the
structural designer
For flanged and other mechanical joints,
acceptable forces are determined by
calculation or consultation with the
manufacturer

Design Criteria Summary

¾ Sustained – maximum stress is 67 to 90%
of the yield stress
¾ Displacement – maximum stress range is
just under twice the yield stress
¾ Reactions – limited to whatever the
manufacturer or other authority says
Flexibility Analysis Example

A two step analysis is shown.
1. Sustained load analysis – verify
proper support and check reactions
2. Displacement load analysis – verify

adequate flexibility and check
reactions

Proposed System
NPS 4 (DN 100)
Carbon Steel
Ambient to 600°F (315°C)
SG contents = 1.0
Sustained Load Analysis
Check Deflections
Deflected 0.4” (10 mm) Marginal:

> 0.3” (8 mm)
Normal
Maximum

Check Reactions 60% = 5%

1020#
(4500 N)
Reactions
Poorly
Distributed
5% 30%

Check Stresses
Max. is 66% of allowable
Stresses
OK


Revised System (Added Support)
60 to 35% 5 to 5%
Max. Displacement –
0.4 to 0.1” (10 to 2 mm)
Max. Stress –
66% to 34% of allowable
Displacements
Stresses &
Reactions
All OK
5 to 10% 30 to 20% 0 to 30%
Displacement Load Analysis

0.4” (10 mm)
Deflections
Check Deflections OK
0.9” (23 mm)


Check Reactions
40% 5%
Reactions
High, Poorly
Distributed
0% 10% 45% =
1240# (5520 N)

Check Stresses
Max. is 79% of allowable Stresses

OK


Revised System (Added Spring
Support)
40 to 0% 5 to 5%
Max. Displacement –
100% =
0.9 to 1.5” (23 to 38 mm) 1240# (5520 N)
Max. Stress –
79% to 48% of allowable Displacements
Stresses &
Reactions
All OK
0 to 0% 10 to 0% 45 to 5%
Is the process of calculating the strains, and
resultant stresses and forces in a piping
system to determine if the system
¾ has adequate support
¾ has sufficient flexibility to safely
accommodate changes in length
resulting from temperature variations
¾ exerts sufficiently low reaction forces at
restraints and equipment

¾ The calculation tools we used have improved
considerably over the last 40 years.
¾ The calculation is still an approximation.
Material properties, and the way they are treated in
calculations are approximations.
No piping is the perfect circular cylinder shape with
uniform wall thickness we assume in the calculations
Restraints are seldom modeled with their actual
flexibilities
Loads used in the calculations (pressure, temperature,
wind, earthquake) are approximations
¾ It is important that the designer understand what
assumptions are conservative, which ones are
liberal, and about how much each assumption
affects the outcome.

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ASME B31.3 Process Piping Course 6.

ASME B31.3 Process Piping

Charles Becht IV, PhD, PE

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 1

Piping Development Process

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 3

The Material in This Section is

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 4

What are we trying to achieve?

2. Provide sufficient flexibility; and

3. Prevent the piping from exerting

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 5

What are we trying to achieve?

January 17 1994 Northridge Earthquake

What are we trying to achieve?

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 7

What are we trying to achieve?

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 8

What are we trying to achieve?

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 9

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 10

Sustained Loads - Weight

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 11

Load controlled (primary)

Sustained Design Criteria

In the absence of more applicable data, W shall be

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 13

Sustained Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 14

Sustained Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 17

Load controlled (primary)

Deformation controlled (secondary)

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 19

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 20

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 21

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 22

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 23

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 24

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 25

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 26

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 27

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 28

Displacement Design Criteria

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 30

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 31

Displacement Design Criteria

BECHT ENGINEERING COMPANY, INC. Flexibility Analysis - 32

Displacement Design Criteria