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Research Paper DEVELOPMENT OF STEAM PIPING …

More et al., International Journal of Advanced engineering Research and Studies E-ISSN2249 8974 Int. J. Adv. Engg. Res. Studies/III/ ,2014/108-113 Research Paper DEVELOPMENT OF STEAM PIPING SYSTEM WITH STRESS ANALYSIS FOR OPTIMUM WEIGHT & THERMAL EFFECTIVENESS 1 Bhairavnath Uttamrao More, 2 Prof. Joshi, 3 Swapnil S. Kulkarni Address for Correspondence 1ME- Mech Product Design and DEVELOPMENT - pursuing, s Textile and engineering Institute, Ichalkaranji, Kolhapur 2 Mechanical Department, s Textile and engineering Institute, Ichalkaranji, Kolhapur 3 Director-Able Technologies India Pvt.

,More et al. International Journal of Advanced Engineering Research and Studies E-ISSN 2249 –8974 Int. J. Adv. Engg. Res. Studies/III/II/Jan.-March.,2014/108 -113

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Transcription of Research Paper DEVELOPMENT OF STEAM PIPING …

1 More et al., International Journal of Advanced engineering Research and Studies E-ISSN2249 8974 Int. J. Adv. Engg. Res. Studies/III/ ,2014/108-113 Research Paper DEVELOPMENT OF STEAM PIPING SYSTEM WITH STRESS ANALYSIS FOR OPTIMUM WEIGHT & THERMAL EFFECTIVENESS 1 Bhairavnath Uttamrao More, 2 Prof. Joshi, 3 Swapnil S. Kulkarni Address for Correspondence 1ME- Mech Product Design and DEVELOPMENT - pursuing, s Textile and engineering Institute, Ichalkaranji, Kolhapur 2 Mechanical Department, s Textile and engineering Institute, Ichalkaranji, Kolhapur 3 Director-Able Technologies India Pvt.

2 Ltd., Pune ABSTRACT This report is about the design of STEAM PIPING and its stress analysis of a given process flow diagram. The prime objective of this project is to design the PIPING system and then to analyze its main components. Wall thicknesses are calculated for all pipes which were found very safe for the operating pressure. For header pipe the calculated wall thickness is mm and the standard minimum wall thickness is mm which is greater than the calculated one by more than times. Different loads such as static loads, occasional loads and thermal loads of all pipes were also calculated. After load calculations, spacing of supports and designing of expansion loops were carried out.

3 Thermal, static and seismic analysis of main system pipe has been done and results were compared with ASME Power PIPING Code After calculation of all applied loads, pipe components were designed and analyzed both manually and on ANSYS software. The results obtained from both methods were compared and found safe under available applied loads. Considering the mathematical model for the PIPING design, the calculations might suggest an under-designed system vis- -vis the relevant CODE. Though, a certain standard exists for a given application, there is enough room to explore the optimization of design since the projects associated with PIPING are normally associated with a high quantum of purchase running in several million rupees to a few billion!

4 Any attempt to rationalize the design would directly improve the savings for the budgetary outlay for the project work while ensuring safety and addressing concerns for potential claims arising due to accidents or malfunction of the system. KEYWORDS- PIPING engineering , Design, Stress Analysis, Expansion loops, CAE software (Ansys) 1] INTRODUCTION Pipes are the most delicate components in any process plant. They are also the busiest entities. They are subjected to almost all kinds of loads, intentional or unintentional. It is very important to take note of all potential loads that a PIPING system would encounter during operation as well as during other stages in the life cycle of a process plant.

5 If we ignore any such load while designing, erecting, hydro-testing, start-up shut-down, normal operation, maintenance etc, It can lead to inadequate design and engineering of a PIPING system. The system may fail on the first occurrence of this overlooked load. Failure of a PIPING system may trigger a Domino effect and cause a major disaster. Stress analysis and safe design normally require appreciation of several related concepts. An approximate list of the steps that would be involved is as follows. 1. Identify potential loads that would come on to the pipe or PIPING system during its entire life. 2. Relate each one of these loads to the stresses and strains that would be developed in the crystals/grains of the Material of Construction (MoC) of the PIPING system.

6 3. Decide the worst three dimensional stress state that the MoC can withstand without failure 4. Get the cumulative effect of all the potential, loads on the 3-D stress scenario in the PIPING system under consideration. 5. Alter PIPING system design to ensure that the stress pattern is within failure limits. The goal of quantification and analysis of pipe stresses is to provide safe design through the above steps. There could be several designs that could be safe. A PIPING engineer would have a lot of scope to choose from such alternatives, the one which is most economical, or most suitable etc. Good PIPING system design is always a mixture of sound knowledge base in the basics and a lot of ingenuity.

7 PIPING System design and analysis is a very important field in any process and power industry. PIPING system is analogous to blood circulating system in human body and is necessary for the life of the plant. The STEAM PIPING system, mentioned in the project will be used for supplying STEAM to different locations at designed temperature and pressure. This PIPING system is one of the major requirements of the plant to be installed. 2] PIPING SYSTEM DESIGN PROCEDURES The following are the steps which need to be completed in mechanical design of any PIPING system. Flow chart: Complete stage designing of PIPING system More et al., International Journal of Advanced engineering Research and Studies E-ISSN2249 8974 Int.

8 J. Adv. Engg. Res. Studies/III/ ,2014/108-113 1 Process Design This process is based on the requirement of the process variables. It defines the required length & cross sectional area of pipe, the properties of fluid inside the pipe, nature & rate of flow in it. These variables affect the positioning and placements of equipments during lay outing and routing. The operating and design working conditions are clearly defined. The end of Process Plan Design is the creation of a Process Flow Diagram (PFD) and Process & Instrumental diagram (P&ID), which are used in the designing & lay outing of the Pipe. 2 PIPING Structural Design In PIPING structural design, according to pressure in pipelines, the design and minimum allowable thicknesses are calculated; according to the required codes and standards.

9 ASME codes for various standards are available, for process fluid flow, ASME (Code for power/ STEAM PIPING ) is used. In the structural design of pipes, when all the loads are calculated then the required span is also calculated for supporting the pipes. ASME covers the minimum requirements for the design, materials, fabrication, erection, testing, and inspection of power and auxiliary service PIPING systems for electric generation stations, industrial institutional plants, and central and district heating plants. The code also covers external PIPING for power boilers and high temperature, high-pressure water boilers in which STEAM or vapor is generated at a pressure of more than 15psig and high-temperature water is generated at pressures exceeding 160 psig or temperatures exceeding 250 F.

10 This code is typically used for the transportation of STEAM or water under elevated temperatures and pressure as mentioned above, so this is the reason that why this code is selected for the STEAM PIPING system which is external to the boiler. Boiler outlet section of the STEAM system comes under the category of ASME Code Power PIPING . In order to ensure the safety of the PIPING system, code requirements should be fully satisfied. For different loads this code incorporates different relationships for stress level as given below .[ ] A] Stresses due to sustained loadings The effects of the pressure, weight, and other sustained loads must meet the requirements of the following equation.


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