Basics of Pipe Stress Analysis

Piping Stress Analysis is the most important activity in Piping Design. Once, pipes are
routed following design guidelines, those needs to be verified by piping stress analysis to
ensure those will work smoothly throughout its design life. This article will explain the
basic points for Piping Stress Analysis. Piping Stress Analysis is also termed as Piping
Flexibility Analysis.

Objectives of Pipe Stress Analysis

Stress Analysis of Critical piping systems are performed to ensure the following objectives.

Structural Integrity:

 Design adequacy for the pressure of the carrying fluid.

 Failure against various loading in the life cycle. Limiting stresses below code allowable.

Operational Integrity:

 Limiting nozzle loads of the connected equipment within allowable values.

 Avoiding leakage at joints.
 Limiting sagging & displacement within allowable values.

Optimal Design:

 Avoiding excessive flexibility and also high loads on supporting structures. Aim towards
an optimal design for both piping and structure.

Governing Codes and Standards for Pipe Stress Analysis

Codes and Standards specify minimum requirements for safe design and construction (i. e.
provides material, design, fabrication, installation, and inspection requirements.)

Following are the codes and standards used for Piping stress analysis of process piping:

1. ASME B31.3: Process piping Code

2. ASME B31.1: Power Piping Code
3. Centrifugal Pumps: API 610
4. Positive Displacement Pumps: API 676
5. Centrifugal Compressors: API 617
6. Reciprocating Compressors: API 618
7. Steam Turbines: NEMA SM23/ API 612
8. Air Cooled Heat Exchanger: API 661
9. Fired Heaters: API 560
 10. Flat Bottom Welded Storage Tanks: API 650
11. Heat Exchangers: TEMA/ Vendor-Specific.
12. Vessel/Column: Vendor-Specific/ ASME Sec VIII
13. ASME B 31.4/ASME B 31.8: Pipeline Stress Analysis
14. ISO 14692: GRE/GRP/FRP Piping Stress Analysis

Stresses in a Piping System

Sources for the generation of stress in a Piping System:

1. Weight
2. Internal/External Pressure
3. Temperature change
4. Occasional Loads due to the wind, seismic disturbances, PSV discharge, etc.
5. Forces due to Vibration.

Sustained Stresses in Piping System

Sustained Stresses are the stresses generated by sustained loads. (e.g. Pressure, Weight). These
loads are present continuously throughout plant life.

Resistive force arising out of sustained stresses balance the external forces keeping the system in
equilibrium. Exceeding sustain allowable stress value causes catastrophic failure of the system.

As per ASME B 31.3, (clause 302.3.5) “ The sum of the longitudinal stresses, SL, in any
component in a piping system, due to sustained loads such as pressure and weight, shall not
exceed “Sh“. Where Sh=Basic allowable stress at the metal temperature for the operating
condition being considered.

Pressure Stresses are taken care of by calculating and selecting proper pipe thickness. The
pressure thickness (t) of a straight pipe can be obtained as per ASME B31.3 from the equation
(Clause 304.1.2) mentioned in Fig.1:
Fig. 1: Equation for Thickness Calculation for Straight Pipe based on ASME B 31.3

Click here to learn pipe thickness calculation in details

Expansion Stresses in Piping System

 Change in length of a pipe of length L due to temp change (ΔT) is given by ΔL=L α ΔT
Here, α =Co efficient of thermal expansion = change in length of unit length element due
to unit change in temp.
 Two “α” values (denoted by A and B) in Code (Table C-1 and C-1M in ASME B31.3
Appendix C):
o The thermal Co-efficient “A” of Table C-1 denotes the mean coefficient of linear
thermal expansion between 70 degrees F to indicated temp (μin/in/0F).
o The thermal Co-efficient “B” of table C-1 denotes total linear thermal expansion
between 70 degrees F to Indicated temp (unit=in/100ft).
o Table C-1M provides thermal co-efficient values in the metric system.
 Expansion stresses are generated when the free thermal growth due to temperature
change is restricted. These are self-limiting or self-relenting.

Stress Intensification Factor in Piping Stress Analysis

SIF( Stress Intensification Factor): This is the ratio of the maximum stress intensity to the
nominal Stress. SIF factors for different components can be obtained from Appendix D of
ASME B31.3 till edition 2018. From ASME B31.3-2020 onwards the Appendix D has been
deleted. Now users are required to use ASME B31J or FEA for finding the values of SIF.

Equations for Calculating Expansion Stress Range and Allowable Stress Value

Displacement Stress Range due to thermal expansion is calculated based on equation SE per
equation 17 from ASME B31.3( clause 319.4.4).

This SE value shall not exceed SA value where SA= Allowable Displacement Stress Range.

As per ASME code B 31.3 (Clause 302.3.5) the allowable displacement stress range (SA) can be
given by the equation (Fig.2):

Fig.2: Equation for

Displacement Stress Range Allowable

Here, f= Stress range reduction factor and Sc=basic allowable stress at minimum metal temp

 When Sh > SL, the allowable stress range is calculated by the following equation (Fig. 3):
SL=Longitudinal Stress due to sustained loads.

Fig.3: Equation for Liberal Displacement Stress Range Allowable

Occasional Piping Stresses

 Occasional Stresses are generated by occasional loads such as Wind, seismic, PSV
discharge, etc.
 These loads act in a piping system for a very small period of time, usually less than 10%
of the total working period.
 As per ASME B31.3, clause 302.3.6 “The sum of the longitudinal stresses, SL, due to
sustained loads, such as pressure and weight, and of the stresses produced by occasional
loads, such as wind or earthquake should be ≤ 1.33 times the basic allowable stress, Sh”
 The code does not explicitly explain the stresses generated due to vibration.
  The vibration problems are solved by engineering judgment and experience.

Reducing Piping stresses

Piping stresses can be reduced by various methods like

 Providing Supports at suitable span to reduce Weight (Sustained) stresses.

 Providing Flexibility to reduce piping expansion stresses generated by thermal loading
Eg. Expansion Loops, Offsets, Inclusion of elbows to change direction.

Flexibility check (as per clause 319.4.1, ASME B 31.3):

Refer Fig. 4

Fig.4: Flexibility Check Equation for Simple Systems

Basic Allowable Stress/ Pipe Material Stress

Minimum of (As per ASME B 31.3)

1. 1/3rd of Ultimate Tensile Strength (UTS) of Material at operating temperature.

2. 1/3rd of UTS of material at room temperature.
3. 2/3rd of Yield Tensile Strength (YTS) of material at operating temperature.
4. 2/3rd of YTS of material at room temp.
5. 100% of average stress for a creep rate of 0.01% per 1000 hr.
6. For structural grade materials basic allowable stress=0.92 times the lowest value obtained
from 1 through 5 above.

Loads on a Piping System

There are two types of loads which act on a piping system: Static loads and Dynamic Loads
Fig.1: Examples of Static Loads

Static loads are those loads that act very slowly and the system gets enough time to react against
it. Examples of static loads are shown in Fig.1
Fig.2: Examples of Dynamic Loads

On the other hand, dynamic loads act so quickly that the system does not get enough time to
react against it. Examples of dynamic loads are shown in Fig.2

Work Flow Diagram for Pipe Stress Analysis

The interaction of the Piping Stress team with other disciplines in any organization is shown in
Fig. 3:
Fig.3: Inter-Departmental Interaction with Stress Team

Stress Criticality and Analysis Methods

  Highly Critical Lines (Steam turbine, Compressor connected pipelines): By Computer
Analysis
  Moderately Critical Lines (AFC connected lines): By Computer Analysis
  Low critical Lines: Visual/Simple Manual Calculation/Computer analysis and
  Non Critical Lines: Visual Inspection

Stress Analysis using Caesar II

Caesar II by Hexagon is the most popular and widely used international pipe stress analysis
software. Pipe stress analysis is normally performed in four steps as listed below:

 Input Collection for Piping Stress Analysis

  Performing the stress analysis
 Interpreting the results and suggesting changes if required
 Providing Recommendation based on Analysis

Inputs required for Piping Stress Analysis:

 Stress Isometric from Layout Group

 Line Designation Table (LDT) or Line List And P&ID from Process
 Equipment GA and Other detailed drawings from Mechanical
 Process flow diagram/datasheet if required from the process
 Piping Material Specification
 PSV/ Control Valve GA and Datasheet from Instrumentation
 Soil Characteristics from civil for underground analysis
 Nozzle load limiting Standards
 Plot Plan for finding HPP elevation and equipment orientation.
 Governing Code

Stress Analysis:

 Checking the completeness of the piping system received as a stress package.

 Node numbering on stress Iso.
 Filling the design parameters (Design temp, pressure, Ope. Temp, Min. Temp, Fluid
density, Material, Line Size and
thickness, Insulation thickness, and density, Corrosion allowance, etc) on stress Iso.
 Modeling the piping system in Caesar using parameters from stress Iso.
 Analyzing the system and obtaining results.

Conclusion & Recommendation:

Whether to accept the system or to suggest necessary changes in layout and supporting to make
the system acceptable as per standard requirements.

Outputs from Stress Analysis:

  Final marked up Iso’s to Layout

  Support Loads to Civil
  Spring Hanger Datasheets.
  Datasheets for Special Supports like Sway brace, Struts, Snubbers, etc.
  SPS drawings
  Stress Package final documentation for records

Other Piping Stress Analysis Software:

There are a few other pipe stress analysis software are available in the market which are used as
alternatives to Caesar II softwares like
  Auto-Pipe by Bentley
 Start-Prof by PASS (Russia)
 Rohr-2 by SIGMA Ingenieurgesellschaft mbH (Germany)
 CAEPIPE by SST Systems Inc (USA)

 Type of Pipe Supports

Pipe Stress Analysis will be incomplete without a few words about piping supports. Piping stress
analysis, in one way is the selection of proper supports and placing them in correct location to
avoid detrimental stresses in the piping systems. Various types of supports are used in the piping
and pipeline industry like

 Rest Support: Restrict downward movements.

 Guide Support: Arrest lateral movements.
 Line Stop or Axial Stop: Restrict axial or longitudinal movement of the pipe.
 Anchor Support: Completely fixed. Restrict all six degrees of freedom. Pipe at this
support point can’t translate or rotate.
 Variable Spring Hanger Support: Flexible support, Act as Resting support with
flexibility to thermal movements.
 Constant Spring Hanger: Flexible support, Act as Rest support allowing thermal
displacements.
 Rigid Hanger: Hanging support from the top.
 Struts: Dynamic Restraint
 Snubbers: Dynamic Restraint
 Sway Braces, etc.

In piping stress analysis supports can be classified in two groups

1. Uni-Directional Piping Support and

2. Bi-Directional Pipe Support.

Unidirectional pipe support is free to move in one direction like +Y, +X, +Z, etc here the
supports are free to move in +y, +x, and +z respectively. However, bi-directional piping support
arrests movement in both direction like Y, X, or Z supports.

Basics of Piping Stress Analysis Tutorial Video

To learn the above-mentioned points in details refer to the following video:

Basics of Pipe Stress Analysis x

Remaining Time -23:21
Basics of Pipe Stress Analysis
Basic Piping Stress Analysis Video Tutorial

Questionnaire for Piping Stress Analysis

  What are the various types of loads which cause stresses in the piping system?
 Which code do we refer to for Refinery Piping?
 Which standard governs the design of Pumps?
 The coefficient of thermal expansion of a substance is 1.8 mm/m/Deg.F. What is its value
in mm/mm/Deg.C.?
 Calculate the minimum pipe thickness of a seamless 10” NB A106- Gr B material with a
design pressure of 20 bars. (Design Temp= 350 degree C and Corrosion allowance= 1.6
mm)?

Few more piping resources for you..

Basic Piping Stress Analysis Articles
Piping Stress Analysis using Caesar II
Piping Stress Analysis using Start-Prof
Piping Design and Layout Basics
Piping Materials Basics
Tutorials on Piping Design Softwares

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Anup Kumar Dey

I am a Mechanical Engineer turned into a Piping Engineer. Currently, I work in a reputed MNC
as a Senior Piping Stress Engineer. I am very much passionate about blogging and always tried
to do unique things. This website is my first venture into the world of blogging with the aim of
connecting with other piping engineers around the world.

14 thoughts on “Basics of Pipe Stress Analysis”

1. Valery Anpilov says:

January 23, 2015 at 12:22 pm

My proposals for the calculations on the strength of pipelines, tanks and pressure vessels.

Calculation of the overall stress-strain state of piping systems made from both metal and
non-metal (including composites) materials, for given values of temperature, pressure,
weight of the internal environment, self-weight of the structure, taking into account the
kinematic conditions, as well as the friction in the bearings.
Calculation of the strength of the joints, bends, tees, valves elements of pipeline systems
involving 3D-geometric and finite element modeling.
Determination of displacements and stresses in the individual fragments of the pipeline
 circuit different geometry in the presence of poles at a given temperature, pressure,
weight of the internal environment on the basis of three-dimensional modeling of
cladding and finite elements.
The calculation of the strength of the underground part of the pipeline at a given
temperature and pressure of the internal environment, taking into account not elastic
properties of the soil (model Mohr-Coulomb, Drucker-Prager, Cam-Clay, Cap-model),
the depth of the pipe, soil temperature, pipe friction on the ground.
Determination of pipes, joints, fittings elements with hydraulic shock.
Estimation of seismic stability of pipeline systems as a whole, as well as separate areas
and support units.
Calculation of the total strength of the static pressure vessels and tanks made of metal and
nonmetal (including composite) materials.
Evaluation of durability and service life of pressure vessels and tanks under cyclic
variation of the parameters of internal and / or external environment.
Seismic resistance of tanks and pressure vessels, including partially filled with liquid –
allowance for the interaction design with a liquid using “technology” – coupled Eulerian-
Lagrangian (CEL) analyses.
Determination hydrodynamic loads “facilities” of fluid flow.

Reply

2. want2learn says:

February 12, 2015 at 9:10 pm

Few nice points has been discussed on this post in linkedin page. Follow this link to
access those: https://www.linkedin.com/groups/http-wwwwhatispipingcom-
basicsofpipestressanalysis-59422.S.5970562625166127107?
view=&item=5970562625166127107&type=member&gid=59422&trk=eml-
group_discussion_new_comment-discussion-title-
link&midToken=AQH3kT0n6EEJKA&fromEmail=fromEmail&ut=0OXgM9Rbpz56E1.

However for the convenience of my readers i am reproducing those here.

By Mr Rao: 
Consultant at DOW chemicals int.pvt.Ltd.
Dear Anup, I have one question ? 
In ceaser analysis all supports are considered as point contact which is not true
practically. 
How does this facilitae accuracy with the effect of friction factor when we are working
with srface contact for supports resting flat..

By Anup Kumar Dey:

Sir, In my opinion The point contact and surface contact does not affect the friction
factor. Only surface roughness of the contact point does. As for example if the contact is
 between CS to CS the friction factor is normally 0.3 or 0.4. It does not reduce when used
as point contact. But if we can make the surface polished then the same will reduce.

By Mr. SATISH KUMAR

Package Design Engineer at Fichtner Consulting Engineers India P Ltd.
Sir, horizontal force applied will be friction factor * normal reaction force.this horizontal
force will be applied against movement of pipe axis.hence place of this force will be
different.

Reply

0. Vijay says:

September 24, 2021 at 4:50 pm

Dear anup sir,

Frictional coefficients are required for guide and limit stop supports?

Reply

3. Zener Gold Medal says:

August 2, 2018 at 2:13 pm

Just want to say your article is as astounding.

The clearness in your post is just cool and i could assume you’re an expert on this
subject.
Well with your permission let me to grab your feed to keep updated with forthcoming
post.
Thanks a million and please carry on the rewarding work.

Reply

4. Nitinkumar says:

March 23, 2020 at 1:21 am

Dear Mr.Anup,
Can you please add step by step manual pipe stress calculation for any piping system on
your blog. It will be easy for a beginner to understand how the pipe stress analysis is
carried out for any piping system and what all steps and checks need to be carried out in
the safe design of a piping system. One cannot see the formulas and methodology used by
 any software to analyse the piping system. It will be a great help for a beginner to
understand all the steps carried out during pipe stress analysis.

Reply

5. Leonor Castro José Satxiema says:

June 10, 2020 at 7:27 pm

Hello,
Do you have any mathcad calculation for Piping stress analysis calculation?

Reply

6. Sachin Laxman Ratnaparkhi says:

July 2, 2020 at 8:22 am

Dear sir First of all thank you for creating the website I am a Mechanical Engineer
studying Piping Stress Analysis. Now SA=f( 1.25SC+ 0.25 Sh)
How to select the value of stress reduction factor f? Is there any criteria or any table to
select it ? Kindly answer.
Thanks and best regards;
Sachin Laxman Ratnaparkhi.
If possible kindly send your mobile nos.I wish to talk to you if you permit .

Reply

7. Sachin Laxman Ratnaparkhi says:

July 2, 2020 at 10:21 am

Dear sir Good day.First of all thank you for the website.Now the point.
SA=f(1.225Sc +0.25Sh)
What is the value of f stress range reduction factor? How can we calculate the value of f?
Thanks and best regards.
Sachin Laxman Ratnaparkhi Mobile no 9082016401,9867242493

Reply

8. Pramod Janardan Bhide. says:

September 21, 2020 at 10:22 am

 Dear Anup,
My self sr.piping designer, and I am retired from MNC company in 2015.
I would like to know extra knowledge of stress analysis books are available in the market,
Pl.send me PDF of these books if you have this books.

Reply

9. Sandip says:

December 29, 2020 at 10:39 am

Do you have any general guidelines for not critical line supporting. As in where to
provide guide and anchors for lines which is not critical for stress analysis.

Reply

10. Jerry Lainhart says:

July 7, 2021 at 2:40 am

The conclusion – accept or not.

Any suggestions on how to evaluate and make a decision on as-built condition compared
to design?

Thanks

Reply

11. Mohammad Zhoobin says:

November 22, 2021 at 11:40 pm

Dear Anup
Thank you for your useable technical information about piping design criteria.
Subject: We want design a 10” pipe line for Demineralization Water for 4 kilometers
length and 20 bar pressure at ambient temp. 36 deg. Celsius.
Design temp. for mechanical is Defined 52 deg Celsius.
Question: is it required to consider expansion loop in the pipe line length?
Regards

Reply
 12. prasad says:

April 16, 2022 at 7:23 pm

I have created two load cases for W+T1, AND T1 for pipe with fixed ends on both sides.
So here what i observed is that is Axial force is more in T1 Case compared to W+T1. Can
you please tell me the reason

Reply

13. prasad says:

April 16, 2022 at 7:39 pm

I have created two load cases for W+T1, AND T1 for pipe with fixed ends on both sides.
So here what i observed is that is Axial force is more in T1 Case compared to W+T1. Can
you please tell me the reason

Reply

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