Stress Analysis of Column piping system

using Caesar II
December 21, 2018 19 Comments

Columns or Towers, used for distilling raw materials (Crude Oils) are very important
equipments in any process industry . Every process piping industry must have several
columns. Lines of various diameter and properties (Process Parameters) are connected to
Columns at different elevations. Stress analysis of all large bore lines connected to column
are required to assess proper supporting and nozzle loading. Looking to the construction of
column, it has number of trays at different elevation. Temperature at each tray location differs
based on process.
In the following article I will try to explain the methodology followed for stress analysis of
Column Piping using Caesar II.

Stress analysis of Column Piping will be discussed in following points: 1. Inputs required for
analysis 2. Temperature profile creation for the column/tower 3. Modelling in Caesar II 4.
Supporting of Column Connected piping system and 5. Nozzle load qualification.

1. Inputs required for Analysis: The following data are required while modeling and
analysing column connected lines:

a) Column G.A.drawing with all dimensions, nozzle orientation, materials etc.

b) Column temperature profile.
c) Line Designation Table/ Line list/Line Parameters and P&ID.
d) Column line ISO.
e) Allowable nozzle load table as specified in Project Specification.

2. Temperature profile for Column/Tower: Different organization uses different methods

for creating column temperature profile. Here I will describe two methods which are most
widely used.

Temperature profiles for towers are normally created based on connected outlet lines. So in
the P&ID mark the big size (big size means nozzle size which will make consideration
impact in temperature change) column outlet nozzles. Then write down the operating and
design temperatures beside those lines from line list. Lets assume that there are three big size
(N1, N2 and N3 as shown in Fig. 1) outlet nozzles in a typical tower. So temperature profile
for that column can be created as shown in Fig. 1. This method is the most widely used
method among prevailing EPC industries.
 Fig. 1: Temperature profile creation for a typical tower- Method 1

Again the temperature profile of the above tower can be generated using the method
mentioned in Fig. 2. Many of the organizations use this method too.
 Fig. 2: Temperature profile Creation for a typical Column -Method 2

Few organisation uses the operating and design temperatures mentioned in equipment GA as
the equipment operating and design temperature. However the above two methods mentioned
will result in thermal growth close to reality.

3. Modeling the Column/Tower in Caesar II: All equipment modeling are almost similar.
Start modeling the tower from the skirt and go up or start from nozzle of interest and go down
till skirt as per your choice. It is a better practice to use node number such a way that the
equipment nodes can easily be separated from the piping nodes. I personally model
equipments starting from node 5000. Lets start from a typical nozzle flange. So model 5000-
5020 as nozzle flange with nozzle diameter and thickness as mentioned in equipment GA
drawing. Sometimes vendor GA may not be available (during initial phase of the project), so
in such situation use engineering drawing as the basis for modeling. Normally mechanical
departments have minimum nozzle thickness chart based on flange rating and corrosion
allowance. Take nozzle thickness from that chart or otherwise assume nozzle thickness as
two size higher than the connected pipe thickness. Use temperatures as mentioned in the
above two diagrams (Fig. 1 or Fig. 2) from flange onwards, pressure, corrosion allowance,
materials, insulation thickness and density etc as mentioned in reference equipment drawing.
Then model 5020 to 10 as pipe element with length from reference drawing (Normally nozzle
projection from equipment centreline in provided, in that case calculate the nozzle length by
subtracting the equipment outside radius and flange length already modelled). Provide
Anchor at node 10 with Cnode at 5040. Providing node number for nozzles as 10, 20 etc will
put all this nodes at initial nodes in restraint summary which helps me in checking nozzle
loads very quickly. You can provide separate nodes if you wish. This completes the nozzle
model. Now we will model the equipment.

Model 5040 to 5060 as rigid body with zero weight with length=half of equipment OD,
material as provided in reference drawing, temperature as mentioned the above figures,
pressure and other parameters from reference equipment drawing. This element will take you
to the center of the equipment. From this part onwards simply model the equipment as pipe
elements taking temperature profile as mentioned in the above figures. Check diameter and
thickness in reference drawing as those values sometimes changes as you proceed from top
towards skirt. Finally model the skirt as pipe element with temperatures calculated as mention
at the last paragraph of this topic and pressures, fluid density, corrosion allowance as zero.
Provide fixed anchor at bottom of skirt. Refer Fig. 3 for a sample model of column. Different
colors are for different temperatures.
 Fig. 3: A simple model of a Tower in Caesar II

4. Supporting of Column Connected Piping System: The pipes are normally supported
from column itself. This type of supports are called cleat supports or clip supports. The first
support from column nozzle is a load taking support which carries the total vertical load of
the pipe. Try to place this load taking support as near to the nozzle as possible. Rest all are
guide supports. As the clips are connected to the tower body we have to model clips from
column and connect the supports with a Cnode to take the thermal effect of that location. The
load bearing capacity of the clip supports are normally standardized by support standard. So
sometimes it may appear that the load at first load taking support is exceeding the clip load
bearing capability (This could happen if a very large size line is connected towards the top of
the column, overhead lines) . In those cases we have to take 2nd support from nozzle as a
load taking support as well. This support has to be a Spring hanger support which will share
part of the load of the first load taking support. From that point onwards guide supports will
be used based on standard guide span as specified in project specification. A sample Caesar II
model is shown in Fig 4 for your reference to explain the clip supports. Model the clip as
rigid body with zero weight with equipment properties when inside equipment and with
ambient temperature when outside equipment.
 Fig. 4: Caesar II model showing Clip/Cleat Supporting

5. Nozzle Load Qualification: Allowable nozzle loads are normally provided by equipment
vendor and mentioned in general arrangement drawing. Few organization has standard load
table based on nozzle diameter and flange rating. So compare your calculated loads at nozzle
anchor point with this allowabale values to find if calculated loads are acceptable or not. If
loads are exceeding the allowable values modify the supporting or routing to reduce your
nozzle loads. In some situation when routing change is not feasible perform WRC as
mentioned in one of my last articles or perform FEA (Nozzle Pro) to check whether
generated stresses are acceptable. In extreme cases send your nozzle loads to vendor for their
acceptance.

Skirt Temperature Calculation:

Calculate skirt temperature following the given equation:

Average Skirt Temperature=(T-Ta)*F+ Ta; in degree centigrade

Here Ta=Ambient Temperature in degree Centigrade; T=Temperature at the top of the skirt;
F=[83.6/{(K*h/t^0.5)+15.5}]; K=insulation constant=1.0 for fire brick insulation=1.6 for non
insulated; h and t are skirt height and thickness respectively.

If you have any confusion please inform in comments section.