FEA Based Pipe Stress Analysis - Introduction To Pipe Calculation System (PCS)

FEA Based Pipe Stress Analysis -
Introduction To Pipe Calculation
System (PCS)
Presented by RMC and VIAS
Carlos Eduardo Alvares
Arindam Chakraborty, PhD, PE

© 2017 Virtual Integrated Analytics Solutions Inc.
Agenda
1 VIAS and RMC Overview
2 Standard Flexibility Methods And Other Available Techniques
3 Overview of PCS
4 Demo
5 Contact Information
6 Q&A
2

About VIAS
Engineering
Consultancy
Training
Hardware
Software
• Multiple Industry Experience – Oil & Gas, Machinery &
Equipment, Petrochemical & Process, Nuclear,
Aerospace, Medical Devices
• Presence in Houston, Cincinnati, San Francisco, Detroit
• Team consists of Ph.D. and Masters in Solid Mechanics,
Fluid Mechanics, Materials and Corrosion, Numerical
Analysis, Statistics; Optimization and Reliability
• Solution partner of Dassault Systèmes SIMULIA products
– Abaqus, Isight, fe-safe, Tosca
• Provide Virtual Design Experience through Collaboration
and Data Analytics – Provides Automation and
Customization
• Provide 3D Printing and AM Simulation Services
4

VIAS Technical Capabilities
Design Analysis and
Validation using
Simulation
FEA based Fracture /
Damage Mechanics /
ECA
Optimization and
Reliability
Multi-physics
Simulations (CFD,
Thermal Analysis)
Composites and
Elastomer modelling
Structural Analysis /
Plant Engineering
Integrity Management –
FFS, RBI
Simulation Automation /
Workflow Development
Corrosion Testing and
Material Test Program
Support
Data Analytics
5

Training at VIAS – In-Class / Online
http://www.viascorp.com/course-schedule/
6

VIAS – Abaqus Support Day
7

About RMC
• Established since 1984;
• Engineering services and software for O&G and Energy
industries.
8

RMC Mission
To provide customers with best in class engineering services
and engineering software products, ensuring them fast, safe,
reliable and profitable operations.
9

RMC Software Products
10

STANDARD FLEXIBILITY METHODS AND
OTHER AVAILABLE TECHNIQUES

• 172 tagged lines
• Large diameters (between 16” and
24”)
• 87snubbers + 165 spring hangers
• Non-standard components
• Temperature range: 0 to 690°C
• Larson-Miller, Time-History e Slug-
Flow
• 54 independent load cases
Coke Drum Analysis by Standard
Flexibility Methods
12

Flexibility & Stress Intensification
Factors
SIFs (i):
• Experimentally developed on the late 40’s.
• Incorporated in ASME B31.3 on 1955.
• Compares fatigue strength of a component against a
standard butt-welded straight pipe.
• In-fact, “i” factors are penalty factors.
• Developed considering displacement controlled loads
only (secondary loads).
• Available for simple components only.
Warnings:
• D/t ratio
• Non-standard components
• Flexibility Factors strongly influences SIFs
• Different weld procedures from the 50’s
• Fatigue from primary loads
• HCF or LCF (penalty factor f)
• Nonlinearities
Flexibility Factors (k):
• Analytically developed on the early 1900’s.
• Extremely dependent on pipe ovalization.
• Valid for small values of h.
• Available for simple components only.
Ref.: ASME-B31.3,"Chemical Plant and Petroleum Refinery Piping", New York, N.Y., (2012).
13

Acknowledging Limitations - The need
for more applicable data
Ref.: ASME-B31.3,"Chemical Plant and Petroleum Refinery Piping", New York, N.Y., (2012).
14

PCS vs. Markl`s Lab Tests
15

Details of a typical pipe specimen
Ref: Vishnuvardhan, S., Raghava, G., Gandhi, P., Goyal, S., Gupta, S. K., and Bhasin, V., 2013,
“Ratcheting Strain Assessment in Pressurised Stainless Steel Elbows Subjected to In-
plane Bending,” Procedia Eng., 55, pp. 666–670.
16

Flexibility Analysis – Available Techniques
TEMPERATURE
PRESSURE
LOW MEDIUM HIGH
LOADING HISTORY
GEOMETRY
17

TEMPERATURE
PRESSURE
LOW MEDIUM HIGH
LOADING HISTORY
GEOMETRY
STANDARD FLEXIBILITY
METHOD
18

TEMPERATURE
PRESSURE
LOW MEDIUM HIGH
LOADING HISTORY
GEOMETRY
STANDARD FLEXIBILITY METHOD
+
NON-STANDARD FEA TOOLS
19

TEMPERATURE
PRESSURE
LOW MEDIUM HIGH
LOADING HISTORY
GEOMETRY
HIGH PERFORMANCE
FINITE ELEMENTS
(ABAQUS)
20

TEMPERATURE
PRESSURE
LOW MEDIUM HIGH
LOADING HISTORY
GEOMETRY
PCS – PIPE CALCULATION SYSTEM
21

Simulia Abaqus
• Linear and nonlinear analysis
• Complex material models
• Complex assemblies
• Contact, fracture & failure capabilities
• Scalability (High-Performance
Computing)
• Open development API
22

Overview of PCS
24

• Internal Databases
• Pipe Routing
• Bends
• Supports
• Hangers
• Rigid
• Pre-processing
• Running
• Input and Output tabular reports:
➢ Human readable.
➢ Evidence of all calculation
assumptions and results.
➢ Easy storage.
• Standard Abaqus .inp files.
• Standard Abaqus .odb files.
Overview of PCS
25

Case Study #1 – Benchmark 24
Benchmark 24:
8”- sch. 40 – API-5L B (~80 m)
Corrosion Allowance: 1.6 mm
Temperature: 70 °C
S.G: 1.0
26

Short Demo
Demo!
27

Case Study #2 – Benchmark 07
Benchmark 07:
14”/16”/18”- STD – API-5L B
(~250 m)
Corrosion Allowance: 1.6 mm
Temperature: 70 °C
S.G: 0.82
Fx [N] Fy [N] Fz [N]
PCS 58,097.0 -33,800.0 144,763.0
Caesar II (No Flg) -28,803.0 27,410.0 -80,066.0
Caesar II (2 Flg) -37,732.0 30,729.0 -101,969.0
28

Case Study #3 – Pipeline Jog
Pipeline Jog:
16”- STD – P22
Temperature: 594 °C
29

Case Study #3 – Pipeline Jog
T=21°C
T=594°C
T=21°C
T=21°C
T=594°C
T=594°C
30

Eng. Carlos Eduardo A. de C. e Sousa
PCS Development Manager / FEA Specialist
eduardo@rmcrs.com.br
Contact Information
RMC Consultoria
www.rmcrs.com.br
www.explorepcs.com
+55 (51) 3335-15-05
Rua 24 de Outubro,
1681/209
90510-003
Porto Alegre – RS – Brazil
RMC Contact Information
32

VIAS Contact Information
Certified Simulia Support and Training
Engineering Consulting, Automation
Email : support@viascorp.com
Phone : +1 (832) 301-0881
33

FEA Based Pipe Stress Analysis - Introduction To Pipe Calculation System (PCS)

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