M.

Balaji / Mechanica Confab ISSN: 2320-2491

OPTIMIZATION OF PIPING LAYOUT WITH RESPECT TO

PRESSURE AND TEMPERATURE USING CAESER-II

M. Balaji
Assistant Professor, Department of Mechanical Science, B. S. Abdur Rahman University,
Chennai.
Corresponding Email: balaji.mech33@gmail.com

Abstract
This work is to optimize the span length, number of supports, and cost of the piping layout by
analyzing through modes such as thermal run, weight run, and final run using CAESER-II.
The geometrical properties such as diameter, thickness, span length were considered during
the design and analysis of the piping layout. The variation of the pipe material density with
respect to change of pressure and temperature of the operating medium was used to vary the
span length between the supports and the number of supports was optimized. The variation of
the pipe material density with respect to change of pressure and temperature of the operating
medium was used to vary the span length between the supports and the number of supports
was optimized.
Keywords: Span Length, Material Density, Operating Medium, Pressure, Temperature.

1. Introduction
Pipe Stress Analysis (PSA) is a complex engineering discipline which covers the design,
analysis and identification of piping problems by ensuring that weight, thermal, and pressure
stresses are at acceptable levels specified in engineering design standards. PSA includes the
calculation of piping code stresses, loads and deflections under static and dynamic loading
conditions. The stress analysis of pipe networks is normally done using the Fnite Element
Method (FEM).
The reasons for the analysis of pipe stresses on a piping system is essential to ensure that
the piping is well supported and does not fall or deflect 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; and that the stresses in the pipe work in cold and hot conditions are under the
range allowed.
PSA addresses problems such as thermal analysis (analysis for free and restrained thermal
growth conditions); deadweight analysis (analysis at ambient temperature with a system of
hangers at specific locations to support the weight of the system, for allowable stress and
reactions at equipment connections) seismic analysis (static or dynamic); wind load analysis

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(static stress analysis); transient analysis (for various transient loading conditions such as,
turbine trip, pipe whip, safety relief valve trip etc.).
1.1. Literature Review
C. Basavaraju [1] has done intensive research on piping systems, materials used,
supports, fittings, insulation properties, operating medium in pipe line and analysed the main
stream line of thermal power plant and provided supports to successful installation. In the
journal, the tertiary supports such as hanger was used.
Mat´as Alvarado [3] has given the basic ideas about the piping analysis software
CAESAR II. PSA is a complex engineering discipline which covers the design, analysis and
identification of piping problems by ensuring that weight, thermal, and pressure stresses are
at acceptable levels specified in engineering design standards, problems such as thermal;
deadweight analysis seismic analysis (static or dynamic); wind load analysis; transient
analysis; dynamic analysis about exchanging data from CAESAR II.
Dr. D. P. Vakharia, Mohamed. Farooq A [6] investigated the piping stresses,
leakage at joints, excessive thrusts and moments on connected equipment, excessive stresses
in supporting, excessive interference with thermal expansion and contraction in piping,
excessive distortion in piping and determined the maximum span based on the maximum
bending stress theory. After the analysis, authors listed the nominal pipe diameter and
suggested maximum span.
1.2. Types of Loads
1.2.1. Primary Loads
These are typically steady or sustained types of loads such as internal fluid
pressure, external pressure, gravitational forces acting on the pipe such as weight of pipe
and fluid, forces due to relief or blow down pressure waves generated due to water
hammer effects. The last two loads are not necessarily sustained loads. All these loads
occur because of forces created and acting on the pipe. In fact, primary loads have their
origin in some force acting on the pipe causing tension, compression, torsion etc. leading
to normal and shear stresses.
1.2.2. Secondary Loads
Just as the primary loads have their origin in some forces; secondary loads are
caused by displacement of some kind. For example, the pipe connected to a storage tank
may be under load, if the tank nozzle to which it is connected moves down due to tank
settlement. Similarly, pipe connected to a vessel is pulled upwards because the vessel
nozzle moves up due to vessel expansion. Also, a pipe may vibrate due to vibrations in
the rotating equipment it is attached to.
A pipe may experience expansion or contraction once it is subjected to
temperatures higher or lower respectively as compared to temperature at which it was
assembled.
The secondary loads are often cyclic, but not always. For example load due to tank
settlement is not cyclic. The load due to vessel nozzle movement during operation is

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cyclic because the displacement is withdrawn during shut-down and resurfaces again after
fresh start-up. A pipe subjected to a cycle of hot and cold fluid similarly undergoes cyclic
loads and deformation. Failure under such loads is often due to fatigue and not
catastrophic in nature.

Figure (1). Above Piping Layout is Taken For Study From Stress Analysis of Piping
System, Chapter B4, Page B.189, Figure B4.23.

1.2.3. Internal/External Pressure

A pipe used for transporting fluid would be under internal pressure load. A pipe such
as a jacketed pipe core or tubes in a Shell & Tube exchanger etc. may be under net
external pressure. Internal or external pressure induces stresses in the axial as well as
circumferential (Hoop’ s) directions. The pressure also induces stresses in the radial
direction.
1.2.4. Bending Load
A pipe can face sustained loads causing bending. The bending moment can be
related to normal and shear stresses. Pipe bending is caused mainly due to two reasons:
Uniform weight load and concentrated weight load. A pipe span supported at two ends

2. Methodology
The piping layout in figure (1) is modeled using CAESAR-II, , THE END OF THE
pipe are rigidly fixed using anchor and the input parameters listed in table(1) are given , then
the analysis of layout is carried out with providing necessary supports,
Then the input temperature and pressure values are varied and their respective
change in spa length in measured and tabulated in table 3, table 4.

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2.1. Input Parameters for Piping Layout

Table 1. Input Parameters for Piping Layout

S. No Parameters Value
400C
1 Operating temperature
2 Operating Pressure 100bar
3 Material A335P22
4 Diameter of pipe 4.5 inch
5 Thickness of pipe 0.5 inch
6 Insulation thickness 2 inch

2.2. Assumptions for Calculations

1) The pipe between two supports (restraints, hanger) was considered as simply
supported beam.
2) The pipe between two supports (anchor) was considered as fixed beam.

Table 2. Data For Analysis As Beam

S. No. Parameters Value

Length between two
1 300mm
supports
Material for pipe carbon
2 7800Kg/m^3
steel
3 Operating medium steam 400,500,600,700C
Operating medium 100,150,175,200,220
4
pressure bar

2.4. Span Length Variation Based on Density of Operating Medium

• Density of the material decreases based on the temperature of operating medium,
• Density of the material increases based on the pressure of operating medium,

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3. Results and Discussion

3.1. Variation of Span Length With Respect To Temperature

Table 3. Variation of Span Length With Respect To Temperature

Temperature Span Length
S. No.
(C) (mm)
1 400 300
2 500 322.40
3 600 344.65
4 700 362.54
5 800 379.44

From the above table 3, the variation of the span length for the various temperatures is
given, as the temperature increases the span length also increases. So the variation of
temperature also should taken in account for the optimization of the piping layout.

3.2. Variation of Span Length With Respect To Pressure

Table 4. Variation of Span Length With Respect To Pressure

Pressure
S. No. Span Length (mm)
(Bar)
1 100 300
2 160 239.65
3 180 222.54
4 200 205.86
5 220 177.01
6 240 159.60

From the above table (4) the variation of the span length for the various pressures is
given, as the pressure increases the span length decreases. So the variation of pressure also
should taken in account for the optimization of the piping layout.

4. Conclusion
1) As per the piping layout taken from the ASME journal Chapter B4 stress analysis of
piping systems, number of hanger (H) used to code stress and displacements check
passed was 9.
2) With the above layout, after analyzing the number of hangers (H)(9) was reduced to
restraints +Y(5), anchors (2).

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3) Density of the piping material and operating medium decreased as the temperature of
operating medium increased.
4) Density of the piping material and operating medium increased as the pressure of
operating medium increased.
5) With the above property as reference, the span length of the piping layout can be
varied and optimized.

References
[1] C. Basavaraju, Senior Engineering Specialist, Bechtel Power Corporation. Maryland
ASME journal, Chapter B4- Stress Analysis of Piping Systems, Page (B.107–B.214).
[2] L. Di. Giacomo, Senior Engineering Specialist, Bechtel Power Corporation. Maryland
ASME Journal, Chapter B5; Piping Supports, Page (B.215-B240).
[3] Mat´as Alvarado, Decision-Making on Pipe Stress Analysis Enabled by Knowledge-
Based Systems/ Knowl Inf Syst (2007) 12(2): Page (255–278).
[4] Peter Smith Piping Materials Selection and Applications-by.
[5] Prabir K. Sen, Hojjat Adeli.International Journal of Pressure Vessels and Piping 83
(2006), Page (447–463), Engineering and Piping Design uide, NOV Fiber Glass
Systems, Page (1-14.31,32,33)
[6] Dr.D.P.Vakharia, Mohamed. Farooq A Determination of maximum span between pipe
supports using maximum bending stress theory,recent trends in engineering volume
1.No.6,May(2009) page 46-49
[7] Pipe Hanger & Support Recommended Specifications, Erico Private Limited- Page (107-
118).
[8] Transactions, SMiRT 16, Washington DC, August 2001, Page (1117-1125).
[9] Noble Energy District 15 Field Operations Office Greeley, Colorado 22 05 29 – 1-22 05
29 – 13.

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