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Stress Analysis of Steam Piping System

Article  in  Journal of Applied Mechanical Engineering · January 2015

DOI: 10.4172/2168-9873.1000158

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Research Article Open Access

Stress Analysis of Steam Piping System

Yogita B Shinger* and Thakur AG
Mechanical Department, Sir Visvesvaraya Institute of Technology, Kopargoan, Maharashtra 422102, India

Abstract
This is about the design of steam piping and its stress analysis of a given process flow diagram. The prime
objective of this project is to design the piping system and then to analyze its main components. Wall thicknesses
are calculated for all pipes which were found very safe for the operating pressure. For header pipe the calculated wall
thickness is 0.114 inch and the standard minimum wall thickness is 0.282 inch which is greater than the calculated
one by more than 2.4 times. Different loads such as static loads, thermal loads of all pipes were also calculated. After
load calculations, spacing supports carried out. Thermal and static analysis of main system pipe has been done and
results were compared with ASME Power Piping Code B31.1. After calculation of all applied loads, standard circular
column of 4 inch nominal size were designed and analyzed both manually and on ANSYS software. The results
obtained from both methods were compared and found safe under available applied loads.

Keywords: Code B31.1; ANSYS; Steam piping d) Structural design of supports manually

Introduction Piping Standard and Codes

Piping System design and analysis is a very important field in Before the selection of codes for the steam piping, a little detail
any process and power industry. Piping system is analogous to blood about codes, standards and its historical background is given below.
circulating system in human body and is necessary for the life of the
Piping code development
plant. The steam piping system, mentioned in the project will be used
for supplying steam to different locations at designed temperature and The increase in operating temperatures and pressures led to the
pressure. This piping system is one of the major requirements of the development of the ASA (now ANSI) B31 Code for pressure piping.
plant to be installed [1]. The goal of quantification and analysis of pipe During the 1950s, the code was segmented to meet the individual
stresses is to provide safe design. There could be several designs that requirements of the various developing piping industries, with codes
could be safe. A piping engineer would have a lot of scope to choose being published for the power, petrochemical and gas Transmission
from such alternatives, the one which is most economical, or most industries among others. The 1960s and 1970s encompassed a period
suitable etc. Good piping system design is always a mixture of sound of development of standard concepts, requirements and methodologies.
knowledge base in the basics and a lot of ingenuity. The aim of the The Development and use of the computerized mathematical models of
project is to design and analyze piping system according to standard piping system have brought analysis, design and drafting to new levels
piping Codes. The design should prevent failure of piping system of sophistication. Codes and standards were established to provide
against over stresses due to: Sustained loadings which act on the piping methods of manufacturing, listing and reporting design data [3]. “A
system during its operating time. While piping stress analysis is used standard is a set of specifications for parts, materials or processes
to ensure: intended to achieve uniformity, efficiency and a specified quality”.
Basic purpose of the Standards is to place a limit on the number of
1) Safety of piping and piping components items in the specifications, so as to provide a reasonable inventory
2) Safety of the supporting structures of tooling, sizes and shapes and verities [4]. Some of the important
document related to piping are:
Basically the sizing of this steam piping has already done and
contained nearly on 750×300m2 area, including 48 pipes and 52 I. American Society of Mechanical Engineers (ASME)
junctions [2]. The detail of the piping system e.g. length of each pipe, II. American National Standards Institute (ANSI)
Nominal Pipe Size (NPS) with pipe no. starting from 208 and ending
on pipe no. 256 are shown from the following Figure 1. The rest of III. American Society of Testing and Materials (ASTM)
the data e.g. inlet and out let velocities of each pipe, inlet and out let IV. Pipe Fabrication Institute (PFI)
pressure of each pipe and inlet and out let temperature of each and
every pipe are arranged which will be used in further calculations.
This project is about the design of steam piping and its stress
analysis of a given process flow diagram. The prime objective of this *Corresponding author: Yogita B Shinger, Mechanical Department, Sir
Visvesvaraya Institute of Technology, Kopargoan, Maharashtra 422102, India, Tel:
project is to design the piping system and then to analyze its main +91-9890634535; E-mail: [email protected]
components (Figure 2).
Received August 28, 2014; Accepted February 28, 2015; Published March 07,
This project includes the following tasks: 2015

a) Process design of the complete piping system Citation: Shinger YB, Thakur AG (2015) Stress Analysis of Steam Piping System .
J Appl Mech Eng 4: 158. doi:10.4172/2168-9873.1000158
b) Structural design of the pipes manually Copyright: © 2015 Shinger YB, et al. This is an open-access article distributed
under the terms of the Creative Commons Attribution License, which permits
c) Stress analysis of the pipes using ANSYS or compatible CAE unrestricted use, distribution, and reproduction in any medium, provided the
software original author and source are credited.

J Appl Mech Eng

ISSN:2168-9873 JAME, an open access journal Volume 4 • Issue 2 • 1000158
Citation: Shinger YB, Thakur AG (2015) Stress Analysis of Steam Piping System. J Appl Mech Eng 4: 158. doi:10.4172/2168-9873.1000158

Page 2 of 5

concerned, B31.1 Power piping is used because of its temperature and

pressure limitations which is discussed below in detail.
B31.1 power piping
This code covers the minimum requirements for the design,
materials, fabrication, erection, testing, and inspection of power
and auxiliary service piping systems for electric generation stations,
industrial institutional plants, and central and district heating plants.
The code also covers external piping for power boilers and high
temperature, high-pressure water boilers in which steam or vapor is
generated at a pressure of more than 15 psig and high-temperature
Figure 1: A conceptual model based on health, safety and ergonomic measures
water is generated at pressures exceeding 160 psig or temperatures
for sustainable workplace improvement that increase working capacity and exceeding 250oF. This code is typically used for the transportation of
decrease workload. steam or water under elevated temperatures and pressure so this is the
reason that why this code is selected for the steam piping system which
is external to the boiler [5].
ASME code requirements
Boiler outlet section of the steam system comes under the category
of ASME Code B31.1 Power. In order to ensure the safety of the piping
system, code requirements should be fully satisfied. For different loads
this code incorporates different relationships for stress level as given
below [6].

Figure 2: Complete stage designing of piping system.

Stresses due to sustained loadings:
The effects of the pressure, weight, and other sustained loads must
V. American Welding Institute (AWS) meet the requirements of the following equation [1].
VI. Nuclear Regulatory Commission (NRC) SL=(PDO/4t)+(0.75i×MA/Z) (1)
On the other side “A code is a set of specifications for analysis, Where,
design, Manufacture and construction of something”. The basic
purpose of code is to provide design criterion such as permissible P=internal pressure, psi
material of construction, allowable working stresses and loads sets D0=outside diameter of pipe, in
[4]. ASME Boiler and Pressure vessel codeB31 used for the design of
commercial power and industrial piping system. This section has the T=nominal wall thickness, in
following sub section [1]. Z=section modulus of pipe, in3
B31.1: For Power Piping. MA=resultant moment due to loading on cross section due to
B31.3: For Chemical plant and Petroleum Refinery Piping. weight and other sustained load, in-lb

B31.4: Liquid transportation system for Hydrocarbons, liquid SL=basic material allowable stress at design pressure, psi.
petroleum gas, and Alcohols. Stresses due to thermal loadings
B31.5: Refrigeration Piping. The effect of thermal expansions must meet the following equations [1],
B31.8: Gas transportation and distribution piping system. iMc/Z≤SA+f(Sh-Sl) (2)
B31.1 Power piping code concerns mononuclear piping such as Where,
that found in the turbine building of a nuclear plant or in a fossil-fueled
power plant. f=stress range reduction factor,
B31.3 code governs all piping within limits of facilities engaged in Mc=range of resultant moment due to thermal expansions, lb-in
the processing or handling of chemical, petroleum, or related products.
SA=allowable stress range for expansions
Examples are a chemical plant compounding plant, bulk plant, and
tank farm. B31.4 governs piping transporting liquids such as crude oil, The rest of term are same as above.
condensate, natural gasoline, natural gas liquids, liquefied petroleum
gas, liquid alcohol, and liquid anhydrous ammonia. These are auxiliary Piping Design Procedure
piping with an internal gauge pressure at or below 15 psi regardless of Process design
temperature. B31.5 covers refrigerants and secondary coolant piping
for temperatures as low as 320oF. B31.8 governs most of the pipe lines This process is based on the requirement of the process variables.
in gas transmission and distribution system up to the outlet of the It defines the required length and cross sectional area of pipe, the
customer’s meter set assembly. Excluded from this code with metal properties of fluid inside the pipe, nature and rate of flow in it. These
temperature above 450oF or below - 20oF. As for as the steam piping is variables affect the positioning and placements of equipments during

J Appl Mech Eng

ISSN:2168-9873, an open access journal Volume 4 • Issue 2 • 1000158
Citation: Shinger YB, Thakur AG (2015) Stress Analysis of Steam Piping System. J Appl Mech Eng 4: 158. doi:10.4172/2168-9873.1000158

Page 3 of 5

lay outing and routing. The operating and design working conditions D0=outside diameter of pipe, in
are clearly defined. The end of Process Plan Design is the creation of a
Di=inside diameter ofpipe, in
Process Flow Diagram (PFD) and Process and Instrumental diagram
(PID), which are used in the designing and lay outing of the Pipe [7]. t=insulation thickness depends upon NPS, in
g=acceleration due to gravity, ft/sec2
Piping structural design
gc=gravitionalconstant, lbm-ft/ft sec2
In piping structural design, according to pressure in pipelines, the
design and minimum allowable thicknesses are calculated; according ρsteel=density of steel, lb/in3
to the required codes and standards. ASME codes for various standards
ρfluid=density of water, lb/in3
are available, for process fluid flow, ASME B31.1 is used [8].
ρinsulation=density of insulation, lb/in3
Pipe thickness calculations Insulation factor depends on the thickness of the insulation of the
Piping codes ASME B31.1 require that the minimum thickness tm pipe.
including the allowance for mechanical strength, shall not be less than
the thickness [2].
Static Loads Calculations
For Static loads calculation, considering a pipe no. 208 and taking
tm=(P×DO/2×S×Eq+P×Y)+A (3)
its section up to first vertical leg of the expansion loop. This pipe is to
Where, be considering as a straight beam with uniformly distributed load [10].
tm=minimum required thickness, inches Design specifications
t=pressure design thickness, inches NPS (Nominal Pipe Size)=8 in=200 mm
p=internal pressure, psig Pipe outer Diameter=8.625 in
D o = outside diameter of pipe, inches Pipe thickness=0.322 in
S=Allowable stress at design temperature(know as hot stress), psi Total (metal +Insulation +Fluid) distributed weight of pipe=50 lb/
ft=4.167 lb/in Section Modulus, Z=16.8 in3
A=allowance additional thickness to provide for material removed
in threading corrosion or erosion allowance ,manufacturing tolerance Moment of Inertia, I=72.5 in4
should also be consider Modulus of Elasticity, E=27.5 Mpsi
Y = coefficient that takes material properties and design temperature For segment A-B as shown in Figures 3-5 below, taking the weight,
into account shear force (Refer Figure 6) and
For temperature below 900ºF, 0.4 may be assumed Moment equation and then using length L1=22.22 ft
Eq=quality factor. W(x)=-Mo(x)-2 + R0(x)-1-w(x)1 –R1(x-a)-1-M1(x-L)-2
Allowable working pressure V(x)=-Mo(x)-1+ R0(x)0 -w(x)1 –R1(x-a)-1-M1(x-L)-2 (6)
The allowable working pressure of a pipe can be determined by M(x)= -Mo(x)0 + R0(x)1 -w(x)2 –R1(x-a)1-M1(x-L)0
Equation [2]
P= 2(S×Eq)×t/(Do-2Yt) (4)
Where,
t=specified wall thickness or actual wall thickness in inches.
For bends the minimum wall thickness after bending should not be
less than the minimum required for straight pipe [9].
Sustained load calculations
Figure 3: Symmetry of header pipe considering as a beam Solving Segment
Sustained loads are those loads which are caused by mechanical A-B.
forces and these loads are present through out the normal operation
of the piping system. These loads include both weight and pressure
loadings. The support must be capable of holding the entire weight
of the system, including that of that of the pipe, insulation, fluid
components, and the support themselves [2].
Pipe weight =(п/4) ×ρsteel×(DO2-Di2)×(g/gc)
Fluidweight=(п/4)×ρfluid×(Di)2)×(g/gc) (5)
Insulation weight=Insulation factor ×ρinsulation×(g/gc) Figure 4: Segement A-B.

J Appl Mech Eng

ISSN:2168-9873, an open access journal Volume 4 • Issue 2 • 1000158
Citation: Shinger YB, Thakur AG (2015) Stress Analysis of Steam Piping System. J Appl Mech Eng 4: 158. doi:10.4172/2168-9873.1000158

Page 4 of 5

R4 = 159 l lb. Maximum Bending Moment (Figure 7) Mmax =

-32741.44533 lb-in at x =799.92 in
Verification from code
The effects of the pressure, weight, and other sustained loads must
meet the requirements of the following equation [1].
SL = PD0 + 0.75ixM A ≤ 1.0Sh
4t Z
Where,
Figure 5: Segment A-B-C. P = Internal Pressure, psi
D o = Out Side diameter of Pipe, in
t = nominal wall thickness, in
Z=Section modulus of pipe, in3
MA=Resultant moment due to weight and other sustained loads, lb-in
S L=Allowable stress at design hot pressure, psi
i =stress intensification factor
193.7×8.625 / (4×0.322) + 0.75 x 1×32700/ (16.8) ≤ 1.0×14400
2756.92 ≤ 14400
Figure 6: Shear force diagram.
2.75 10 3
≤ 14.4×103

Integrating the moment equation twice and putting boundary Piping Analysis on ANSYS
conditions we get,
Analysis was performed for the pipe in ANSYS for using the
EIy(x) =-M0 (x)2/2 +R0(x)3/6 –w(x)4/24 =0 (7) following data.
As the segment AB,x=L1=266.64 in Element type=Beam 3
-M0(l1) /2 +RO(l1) /6-w(l1) /24 =0
2 3 4
Material properties
-35548.44M0+315945.77R0-877634043.8=0 Modulus of Elasticity=27.5 Mpsi
EIy(l2)=- MO(l2) +R0(l2) /6 +R1(l2-l1) /6-w(l2) /24 =0
2 3 3 4
(8) Poison’s Ratio=0.283
-142193.78M0+252766366.2R0+3159545.78R1-1.404e =0 10
Density=0.283 lb/in3
Similarly for segment C-D: Type of Loads
EIy(l3)=-MO(l3)2+R0(l3)3/6+R1(l3-l1)3/6-R2(l3–l2)3/6-w(l3)4/24=0 (9) Four Vertical constraints in the middle and one all degree of
Freedom constrained at the start.
-320000M0 +85333333.33R0 +25287743.4R1 +3159545.78R2-7.11e11 =0
Gravity=9.81(386.22 in/sec2)
For segment D-E:
Final Meshing=96 elements for total length of the beam (Figures
EIy(l4)=-MO(l4)2 +R0(l4)3/6 +R1(l4-l1)3/6- R 2(l4 –l2)3/6+R3(l4 –l3)3/6
8-10) (22 elements for first four each sections and 8 elements for the
–w(l3)4/24 =0 (10) last section. Refining the mesh from 24 elements up to 96 elements but
568775.12M0+202210929R0+85307735.9R1+252776366.2R2+31567 there is no change found in deformation values and bending moment
02R3 -2.24e11=0 values).
Now taking summation of moment at left end of right end support
M0+R0l4 +R1(l4 –l1)+R2(l4 -l2) + R3(l4 –l3) –wl1(l4 –a) –w(l2 –l1)(l4 –b)-
w(l3 –l2)(l4 –c)-w(l3 –l2) (l4 –c)-w(l4 -l3)(l4 –d)-wx2/2-P×x=0 (11)
M0+1066.56R0 +800R1 +533.28R2 +266.64R3-2369952.574=0
Solving the above (7),(8),(9),(10),(11) equation we get
Mo = -24401 lb.in,Ro= 552 lb, R1=1123 lb R2=1067 lb,
R3= 1266 lb
For R4,taking
R0 +R1 +R2+R3+R4 =wL + 800 Figure 7: Bending moment diagram.

J Appl Mech Eng

ISSN:2168-9873, an open access journal Volume 4 • Issue 2 • 1000158
Citation: Shinger YB, Thakur AG (2015) Stress Analysis of Steam Piping System. J Appl Mech Eng 4: 158. doi:10.4172/2168-9873.1000158

Page 5 of 5

Comparison of analysis
The maximum deflections and bending moment values obtained
from both methods are arranged in Table 1.

Results and Discussion

From the results obtained both manually and on ANSYS, the
difference in maximum deflection is 6.4% where on the other hand
the difference in the max. Bending moment is 1.35%. Deformation is
less than 0.1 inch and also the maximum bending stress is 1947.55 psi
which is quite less than the allowable stress of the pipe.

Conclusion
Following conclusions are made from the analysis of the designed
Figure 8: Loaded view of meshed beam. system.
1. The designed pipe verified all the conditions defined by the ASME
Boiler and Pressure Vessel code B31.1. Thickness and working
pressure calculated are in the safe limit. Thermal and Sustained
analysis results obtained are in the safe limits defined by the Code.
2. Supporting Assembly confirms to the safety requirements of AISC
standards.
3. The analysis shows that the complete system is safe and the results
are verified by manual calculations and ANSYS software.
4. On the positive side of the manual calculations lays the fact that
it gives fully basic concept of the piping system. While the
assumptions made during manual calculations make the results
slightly differ from the software results.
References
1. Li M, Manohar LA (2011) Stress analysis of non-uniform thickness piping
system with general piping analysis software, Nuclear Engineering & Design
241: 555-56.

2. De Melo FJMQ, Oliveira CAM, Fonseca EMM (2009) The thermal and
mechanical behavior of structural steel piping, International Journal of Pressure
Vessels and Piping 82: 145-15.
Figure 9: Deflection (inch) in pipe.
3. Mathan G, Siva Prasad N (2011) Study of dynamic response of piping system
with gasketed flanged joints using finite element analysis, International Journal
of Pressure Vessels and Piping.

4. Martin M. Schwarz (2004) Flexibility analysis of the vessel-piping interface,

International Journal of Pressure Vessels and Piping 81: 181-189.

5. Fu-Zhen X, Pei-Ning L (2004) Finite element-based limit load of piping branch

junctions under combined loadings, Nuclear Engineering and Design 231:141-150.

6. The American Society of Mechanical engineers, ASME B31.1-2001 Power

piping, revised edition.

7. Sam K (2006) Introduction to pipe stress analysis, John Wiley & Sons, USA.

8. Shigley JE, Mischke CR (2000) Mechanical Engineering Design, 5th edition,

McGraw-Hill Book Co.2000.

9. Spirax Sarco Company Ltd. (2008) Supports and Expansion Loops,

International Site for spirax sarco.

10. TPC Training system, Piping system, A Dun & Brad Stress Comp. 1999.

Figure 10: Bending stress (psi) in pipe.

Method Max. Deflection (in) Max. Bending (lb-in)

Manual 0.064 32741.445
ANSYS Results 0.0596 32921.00
Table 1: Comparision of analysis of beam.

J Appl Mech Eng

ISSN:2168-9873, an open access journal Volume 4 • Issue 2 • 1000158

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