PAGMI PHASE I PROJECT

PROJECT NO.3235-200
U-724-PAG-I04-08-T-002

PIPNG STRESS ANALYSIS

DESIGN GUIDE

REFERENCES

ATTACHMENTS

• Pressure Vessel Allowable Nozzle Loads

CLIENT: PDVSA GAS

REV. DATE Total DESCRIPTION OF THE CHANGE ISSUED BY REVISED BY REVISED BY

Pag. ENPPI ENPPI PDVSA GAS

0 26/12/2007 11 ISSUED FOR DESIGN TE MA MV

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CONTENTS

Page

1.0 SCOPE 3

2.0 STANDARD PRACTICE 3

3.0 CRITICAL LINES SELECTION CRITERIA 4

4.0 EXTERNAL LOAD LIMITS ON EQUIPMENT 5

5.0 FRICTION EFFECTS 6

6.0 SUPPORTING 6
GFL 003-0405

APPROVED BY (ENPPI): APPROVED BY (ENPPI): APPROVED BY (PDVSA):

SIGN ___________ SIGN __________ SIGN ___________

POSITION: DEPARTMENT LEADER POSITION: ENGINEERING MANAGER POSITION:
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1.0 SCOPE

The following will cover the Basic requirements for the engineering of piping systems and
components for thermal flexibility, support, pressure, vibration, fluid or gas flow reactions and
environmental factors, including effects on equipment.

2.0 STANDARD PRACTICE

The practices outlined herein are minimum requirements to which the stress analyst shall
adhere in the execution of his activities to ensure adequate engineering review of piping
systems. Flexibility and stress analysis shall conform to piping code ASME B31.3. The piping
Line List for the project shall be the controlling document establishing individual line parameters,
with the piping drawings defining line configurations.

Piping flexibility shall be obtained through pipe routing or expansion loops unless limitations of
space or economics dictate the use of flexible connectors. Expansion loops when installed in a
horizontal plane, shall be offset vertically to clear adjacent piping. Flexible connectors will be
used ONLY when it is not feasible to provide flexibility by other means.

The flexibility analysis shall consider the most severe design temperature condition sustained
during star-up, normal operation, shutdown, or regeneration. The analysis shall be for the
maximum temperature differential. The metal temperature for each condition will be the
temperature of the contained fluid. The effect of minimum and maximum installation and solar
temperature shall be considered in determining the maximum temperature differential.
Installation temperature shall be assumed as 15.6°C and the maximum metal temperature from
the effect of solar radiation shall be taken as 65 °C with no flow in the line, for pipe stress
analysis purposes.

Design pressure from the piping Line List shall be used for all calculations.

All Vessels which may have residual vapors or liquid, creating a hazard to maintenance
personnel, shall be considered subject o steam purge unless linings or catalyst dictate other
methods of purging. Lines which cannot be disconnected during purging shall be designed with
sufficient flexibility to accommodate the thermal displacement of the vessel.

Only hydrocarbon lines within units areas and unit pipeways shall be considered subject to
steam purge. Interconnecting pipeway lines will not be considered as subject to steam purge.
Lines subject to steam purging shall be designed for a temperature of 148 °C or the design
temperatures of the line, whichever is higher.

An impact factor of 2 shall be provided for pressure relief and safety valve reaction.

Should the potential exist, the effects of water-hammer on long lines subject to abrupt stoppage
of flow will be investigated.
GFL 003-0405

APPROVED BY (ENPPI): APPROVED BY (ENPPI): APPROVED BY (PDVSA):

SIGN ___________ SIGN __________ SIGN ___________

POSITION: DEPARTMENT LEADER POSITION: ENGINEERING MANAGER POSITION:
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3.0 CRITICAL LINES SELECTION CRITERIA

3.1 PIPING STRESS ANALYSIS CRITICALITY REQUIREMENTS

CRITICAL LINES are those lines whose flexibility are necessarily to be checked by pipe
stress analysis engineer using computer software (namely, CAESAR II version 4.5) to
calculate the stresses and restraint forces in the piping system.

NON-CRITICAL LINES are those lines for which a detailed flexibility review is not
necessary, and can be evaluated by comparison with previously analyzed lines, manual
simple calculations and/or quick visual check.

3.2 DEFINITION OF CRITICAL LINES

CRITICAL LINES are those falling in any of the following categories:

3.2.1 All process lines connected to rotating machines (e.g. pumps and compressors).

3.2.2 All Process lines connected fired heaters and steam generators.

3.2.3 All lines 6" NPS and larger connected to stationary equipment (e.g. pressure
vessels and air coolers).

3.2.4 All lines containing expansion joints, lines with internal refractory lining and
jacketed lines.

3.2.5 All lines subjected to relatively large differential settlements.

3.2.6 All lines subjected to dynamic impact loads such as slug flow or water hammer.

3.2.7 All non-metallic process lines.

3.2.8 All lines whose size and temperature combination falls in the CRITICAL LINE zone
shown in Figure-1.
GFL 003-0405

APPROVED BY (ENPPI): APPROVED BY (ENPPI): APPROVED BY (PDVSA):

SIGN ___________ SIGN __________ SIGN ___________

POSITION: DEPARTMENT LEADER POSITION: ENGINEERING MANAGER POSITION:
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Figure-1 Pipe Stress Analysis Criticality Criteria Pipe Sizes –Temperature Combination

4.0 EXTERNAL LOAD LIMITS ON EQUIPMENT

Piping to small vertical in-line pumps (20 Hp or less) shall be supported immediately adjacent to
suction & discharge flanges by means of conventional pipe supports. Piping loads shall be
determined with the pump considered as a rigid but unanchored segment of the piping system.

Piping to larger vertical pumps furnished with casing footmounts shall be supported on suitable
foundations.

For in-line and centrifugal pumps, the allowable force and moment limitations at pump nozzles
shall be as much as 2 times the values listed on API 610, according with Appendix F.

The maximum allowable forces and moments which may be applied to centrifugal compressor
flanges by the piping shall be limited to 3 times the values allowed by NEMA Publication SM 23,
part 8 or manufacturer’s limitation. Supporting shall be arranged so that there is no dead load
on the compressor nozzles.

Allowable external forces and moments shall be limited to those that produce limiting stress as
set by ASME B31.3 for the exchanger nozzle/shell material, recognizing stress intensification
factors as determined by the applicable code.

For pressure vessels and miscellaneous equipments, allowable loads shall be as per
Attachment 1.
GFL 003-0405

APPROVED BY (ENPPI): APPROVED BY (ENPPI): APPROVED BY (PDVSA):

SIGN ___________ SIGN __________ SIGN ___________

POSITION: DEPARTMENT LEADER POSITION: ENGINEERING MANAGER POSITION:
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To avoid leakage in flanges, bending moments and forces on flanges 30" and larger shall be
checked by Caesar II flange leakage analysis tool which can be compared to ASME section VIII
Division 1.

Flare system design shall be performed considering ONLY vapor flow. Restrains and structures
shall be sized on this basis. There shall be no consideration or design made for liquid slug flow
in flare systems.

The effect of tanks/vessels settlement on equipment nozzles shall be considered according to

the soil report and foundation type.

5.0 FRICTION EFFECTS

Anchor design in piping systems shall include the effect of frictional resistance to thermal
movement of the pipe based on a coefficient of friction of 0.3 for steel-to-steel contact, and 0.15
for Teflon-to-stainless steel.

The effect of piping weight and friction forces due to thermal expansion shall be included in the
evaluation for loads on mechanical equipment nozzles.

When specifying Teflon pads, the upper slide surface shall be 2 mm thick stainless steel
attached to a structural member which completely covers the Teflon at all times to eliminate the
possibility of ridging or damage to the Teflon surface. The finish on the stainless steel plate
shall be a number 2B finish. Provision shall be made to ensure that the stainless steel plate and
the Teflon surface are not painted.

6.0 SUPPORTING

Pipe supports shall be as per Project specification #S060473202DM43000.

Piping deflection due to dead weight shall be limited to 10 mm maximum for pipe sizes 12" and
smaller. For pipes larger than 12", the bending stress due to dead weight shall be limited to
3000 psi.

Large diameter thin wall lines supports will be as per table shown in Project specification
#S060473202DM43000, Detail #PD-004-05.

Restraints shall be designated for hydrotest, thermal expansion, dead weight, wind, earthquake
and friction loads. Wind and earthquake loads shall be assumed to act independently of each
other.

Design wind velocity, pressure and height zones shall be as per ASCE7, as well as applicable
PDVSA and COVENIN standards.
GFL 003-0405

APPROVED BY (ENPPI): APPROVED BY (ENPPI): APPROVED BY (PDVSA):

SIGN ___________ SIGN __________ SIGN ___________

POSITION: DEPARTMENT LEADER POSITION: ENGINEERING MANAGER POSITION:
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Design for seismic loads shall be per UBC, as well as applicable PDVSA and COVENIN
standards.

In pipe ways only, cold spring may be used in the longitudinal direction of the rack to reduce
interferences caused by thermal expansion of pipe.

Piping systems will not be analyzed for vibrations. There are no process conditions or
equipment specified, at this time, which could induce piping vibrations.

The recommended values of maximum calculated forces

a. - Sustained: Until 90% allowable stress (best 65%)

b. - Expansion: Until 90% allowable stress (best 75%)
GFL 003-0405

APPROVED BY (ENPPI): APPROVED BY (ENPPI): APPROVED BY (PDVSA):

SIGN ___________ SIGN __________ SIGN ___________

POSITION: DEPARTMENT LEADER POSITION: ENGINEERING MANAGER POSITION:
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ATTACHMENT 1

PRESSURE VESSEL ALLOWABLE NOZZLE LOADS

GFL 003-0405

APPROVED BY (ENPPI): APPROVED BY (ENPPI): APPROVED BY (PDVSA):

SIGN ___________ SIGN __________ SIGN ___________

POSITION: DEPARTMENT LEADER POSITION: ENGINEERING MANAGER POSITION:
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VESSEL ALLOWABLE NOZZLE LOAD

FLANGE RATING 150# & 300#

NOTE : Each value shown below indicates a range from minus that value to plus that value with respect to the indicated axis.

NOZZLE SIZE,
SEQ. FR, KN FL, KN FC, KN MT, KN.m MC, KN.m ML, KN.m
in

1 1.5 1.956 2.934 2.934 0.405 0.238 0.330

2 2 2.400 3.600 3.600 0.625 0.378 0.502
3 3 3.552 5.328 5.328 1.346 0.810 1.082
4 4 4.596 6.894 6.894 2.244 1.338 1.874
5 6 6.672 10.008 10.008 4.858 2.895 3.872
6 8 8.760 13.140 13.140 8.210 4.910 6.556
7 10 11.028 16.542 16.542 12.760 7.630 10.173
8 12 13.080 19.620 19.620 17.873 10.727 14.300
9 14 14.232 21.348 21.348 21.560 12.936 17.248
10 16 16.296 24.444 24.444 28.151 16.887 22.519
11 18 18.432 27.648 27.648 35.622 21.384 28.503
12 20 20.292 30.438 30.438 43.956 26.382 35.182
13 22 22.296 33.444 33.444 53.214 31.926 42.574
14 24 24.384 36.576 36.576 63.325 37.998 50.662
15 26 26.645 39.967 39.967 74.330 44.598 59.547
16 28 28.694 43.042 43.042 86.206 51.723 69.061
17 30 30.744 46.116 46.116 98.960 59.376 79.279
18 32 32.794 49.190 49.190 112.595 67.557 90.202
19 34 34.843 52.265 52.265 127.109 76.265 101.830
20 36 36.893 55.339 55.339 142.503 85.502 114.162
21 38 38.942 58.414 58.414 158.776 95.266 127.199
22 40 40.992 61.488 61.488 175.930 105.558 140.941
23 42 43.042 64.562 64.562 193.962 116.377 155.387
24 44 45.091 67.637 67.637 212.875 127.725 170.538
25 46 47.141 70.711 70.711 232.667 139.600 186.394
26 48 49.190 73.786 73.786 253.339 152.003 202.955
27 50 51.240 76.860 76.860 274.890 164.934 220.220
28 52 53.290 79.934 79.934 297.321 178.393 238.190
29 54 55.339 83.009 83.009 320.632 192.379 256.865
30 56 57.389 86.083 86.083 344.822 206.893 276.244
31 58 59.438 89.158 89.158 369.892 221.935 296.328
32 60 61.488 92.232 92.232 395.842 237.505 317.117

FR NOZZLE LOAD APPLICATION FR

POINT
NOZZLE LOAD APPLICATION
ML @ NOZZLE-SHELL MC POINT
INTERSECTION
MT MT @ NOZZLE-SHELL
FL FC INTERSECTION
PIS-25-0400

FC CIRCUMFERENTIAL FORCE MC CIRCUMFERENTIAL MOMENT

FL LONGITUDINAL FORCE ML LONGITUDINAL MOMENT
FR RADIAL FORCE MT TORSIONAL MOMENT
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VESSEL ALLOWABLE NOZZLE LOAD

FLANGE RATING 600# & 900#

NOTE : Each value shown below indicates a range from minus that value to plus that value with respect to the indicated axis.

NOZZLE SIZE,
SEQ. FR, KN FL, KN FC, KN MT, KN.m MC, KN.m ML, KN.m
in

1 1.5 2.445 3.668 3.668 0.506 0.297 0.413

2 2 3.000 4.500 4.500 0.781 0.473 0.627
3 3 4.440 6.660 6.660 1.683 1.012 1.353
4 4 5.745 8.618 8.618 2.805 1.672 2.343
5 6 8.340 12.510 12.510 6.072 3.619 4.840
6 8 10.950 16.425 16.425 10.263 6.138 8.195
7 10 13.785 20.678 20.678 15.950 9.537 12.716
8 12 16.350 24.525 24.525 22.341 13.409 17.875
9 14 17.790 26.685 26.685 26.950 16.170 21.560
10 16 20.370 30.555 30.555 35.189 21.109 28.149
11 18 23.040 34.560 34.560 44.528 26.730 35.629
12 20 25.365 38.048 38.048 54.945 32.978 43.978
13 22 27.870 41.805 41.805 66.517 39.908 53.218
14 24 30.480 45.720 45.720 79.156 47.498 63.327
15 26 33.306 49.959 49.959 92.913 55.748 74.434
16 28 35.868 53.802 53.802 107.757 64.654 86.326
17 30 38.430 57.645 57.645 123.701 74.220 99.099
18 32 40.992 61.488 61.488 140.744 84.446 112.753
19 34 43.554 65.331 65.331 158.886 95.332 127.287
20 36 46.116 69.174 69.174 178.129 106.877 142.703
21 38 48.678 73.017 73.017 198.471 119.082 158.999
22 40 51.240 76.860 76.860 219.912 131.947 176.176
23 42 53.802 80.703 80.703 242.453 145.472 194.234
24 44 56.364 84.546 84.546 266.094 159.656 213.173
25 46 58.926 88.389 88.389 290.834 174.500 232.993
26 48 61.488 92.232 92.232 316.673 190.004 253.693
27 50 64.050 96.075 96.075 343.613 206.168 275.275
28 52 66.612 99.918 99.918 371.651 222.991 297.737
29 54 69.174 103.761 103.761 400.790 240.474 321.081
30 56 71.736 107.604 107.604 431.028 258.617 345.305
31 58 74.298 111.447 111.447 462.365 277.419 370.410
32 60 76.860 115.290 115.290 494.802 296.881 396.396

FR NOZZLE LOAD APPLICATION FR

POINT
NOZZLE LOAD APPLICATION
ML @ NOZZLE-SHELL MC POINT
INTERSECTION
MT MT @ NOZZLE-SHELL
FL FC INTERSECTION
PIS-25-0400

FC CIRCUMFERENTIAL FORCE MC CIRCUMFERENTIAL MOMENT

FL LONGITUDINAL FORCE ML LONGITUDINAL MOMENT
FR RADIAL FORCE MT TORSIONAL MOMENT
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VESSEL ALLOWABLE NOZZLE LOAD

FLANGE RATING 1500# & UP

NOTE : Each value shown below indicates a range from minus that value to plus that value with respect to the indicated axis.

NOZZLE SIZE,
SEQ. FR, KN FL, KN FC, KN MT, KN.m MC, KN.m ML, KN.m
in

1 1.5 3.056 4.584 4.584 0.633 0.371 0.516

2 2 3.750 5.625 5.625 0.976 0.591 0.784
3 3 5.550 8.325 8.325 2.104 1.265 1.691
4 4 7.181 10.772 10.772 3.506 2.090 2.929
5 6 10.425 15.638 15.638 7.590 4.524 6.050
6 8 13.688 20.531 20.531 12.829 7.673 10.244
7 10 17.231 25.847 25.847 19.938 11.921 15.895
8 12 20.438 30.656 30.656 27.926 16.761 22.344
9 14 22.238 33.356 33.356 33.688 20.213 26.950
10 16 25.463 38.194 38.194 43.986 26.386 35.186
11 18 28.800 43.200 43.200 55.660 33.413 44.536
12 20 31.706 47.559 47.559 68.681 41.223 54.973
13 22 34.838 52.256 52.256 83.146 49.885 66.523
14 24 38.100 57.150 57.150 98.945 59.373 79.159
15 26 41.633 62.449 62.449 116.141 69.685 93.043
16 28 44.835 67.253 67.253 134.696 80.818 107.908
17 30 48.038 72.056 72.056 154.626 92.775 123.874
18 32 51.240 76.860 76.860 175.930 105.558 140.941
19 34 54.443 81.664 81.664 198.608 119.165 159.109
20 36 57.645 86.468 86.468 222.661 133.597 178.378
21 38 60.848 91.271 91.271 248.088 148.853 198.749
22 40 64.050 96.075 96.075 274.890 164.934 220.220
23 42 67.253 100.879 100.879 303.066 181.840 242.793
24 44 70.455 105.683 105.683 332.617 199.570 266.466
25 46 73.658 110.486 110.486 363.542 218.125 291.241
26 48 76.860 115.290 115.290 395.842 237.505 317.117
27 50 80.063 120.094 120.094 429.516 257.709 344.094
28 52 83.265 124.898 124.898 464.564 278.738 372.172
29 54 86.468 129.701 129.701 500.987 300.592 401.351
30 56 89.670 134.505 134.505 538.784 323.271 431.631
31 58 92.873 139.309 139.309 577.956 346.774 463.013
32 60 96.075 144.113 144.113 618.503 371.102 495.495

FR NOZZLE LOAD APPLICATION FR

POINT
NOZZLE LOAD APPLICATION
ML @ NOZZLE-SHELL MC POINT
INTERSECTION
MT MT @ NOZZLE-SHELL
FL FC INTERSECTION
PIS-25-0400

FC CIRCUMFERENTIAL FORCE MC CIRCUMFERENTIAL MOMENT

FL LONGITUDINAL FORCE ML LONGITUDINAL MOMENT
FR RADIAL FORCE MT TORSIONAL MOMENT