M6WRP15-15

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STRESS ANALYSIS OF STEAM PIPELINES OF 2×100 MW CAPTIVE POWER PLANT
BY CAESAR SOFTWARE
Thesis · May 2015
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STRESSANALYSISOFSTEAMPIPELINESOF2×100MW
CAPTIVEPOWERPLANTBYCAESARSOFTWARE
A thesis submitted toward partial fulfillment of the requirements
for the degree of
MASTER OF ENGINEERING
in Water Resources and Hydraulic Engineering
Course affiliated toFaculty of Engineering & Technology
Jadavpur University
submitted by
SUKANTA MONDAL
Exam Roll No: M6WRP15-15
Under the guidance of
Dr. RAJIB DAS
Assistant Professor
School of Water Resources Engineering, Jadavpur University
&
Dr. SUBHASISH DAS
Assistant Professor
School of Water Resources Engineering, Jadavpur University
School of Water Resources Engineering
M.E. (Water Resources & Hydraulic Engineering) course affiliated to
Faculty of Engineering & Technology
Jadavpur University
Kolkata 700032, India
2015
i
Declaration of Originality and Compliance of Academic Ethics
I hereby declare that this thesis contains literature survey and original research
work by the undersigned candidate, as part of my Master of Engineering in Water
Resources & Hydraulic Engineering in the Faculty of Interdisciplinary Studies,
Jadavpur University during academic session 2014-15.
All information in this document have been obtained and presented in accordance
with academic rules and ethical conduct.
I also declare that, as required by these rules and conduct, I have fully cited and
referenced all material and results that are not original to this work.
Name
: Sukanta Mondal
Exam Roll Number
: M6WRP15-15
Thesis Title
: STRESS ANALYSIS OF STEAM PIPELINES OF
2×100 MW CAPTIVE POWER PLANT BY
CAESAR SOFTWARE
Signature with Date
:
iii
M.E.(WaterResources&HydraulicEngg.)courseaffiliatedto
FacultyofEngineering&Technology
JadavpurUniversity
Kolkata,India
Certificate of Recommendation
This is to certify that the thesis entitled “STRESS ANALYSIS OF STEAM
PIPELINES OF 2×100 MW CAPTIVE POWER PLANT BY CAESAR
SOFTWARE”is a bonafide work carried out by Mr. Sukanta Mondal under
our supervision and guidance for partial fulfillment of the requirement for the
Post Graduate Degree of Master of Engineering in Water Resources &
Hydraulic Engineering during the academic session 2014-2015.
THESIS ADVISOR
THESIS ADVISOR
Dr. Rajib Das
Assistant Professor
School of Water Resources Engineering
Jadavpur University
Dr. Subhasish Das
Assistant Professor
School of Water Resources Engineering
Jadavpur University
DIRECTOR
Prof. (Dr.) Asis Mazumdar
School of Water Resources Engineering
Jadavpur University
DEAN
Prof. (Dr.) Asis Mazumdar
Faculty of Interdisciplinary Studies, Law & Management
Jadavpur University
v
M.E.ȋWaterResources&HydraulicEngg.Ȍcourseaffiliatedto
FacultyofEngineering&Technology
JadavpurUniversity
Kolkata,India
CERTIFICATE OF APPROVAL **
This foregoing thesis is hereby approved as a credible study of an engineering
subject carried out and presented in a manner satisfactorily to warranty its
acceptance as a prerequisite to the degree for which it has been submitted. It is
understood that by this approval the undersigned do not endorse or approve any
statement made or opinion expressed or conclusion drawn therein but approve the
thesis only for purpose for which it has been submitted.
Committee of
Final Examination
for the evaluation
of the thesis
** Only in case the thesis is approved.
vii
ACKNOWLEDGEMENT
_____________________________________________________
I express my sincere gratitude to my supervisors Dr. Rajib Das and Dr. Subhasish Das
under whose supervision and guidance this work has been carried out. It would have
been impossible to carry out this thesis work with confidence without their wholehearted
involvement, advice, support and constant encouragement throughout. They have not
only helped me in my thesis work but also have given valuable advice to proceed further
in my life. I would never forget the valuable help that I received from Prof. (Dr.) Asis
Mazumdar, Dean, Faculty of Interdisciplinary Studies, Law & Management &
Director, School of Water Resources Engineering, Jadavpur University.
I also express my sincere gratitude to Dr. Debasri Roy, Associate Professor; Prof. (Dr.)
Arunabha Majumder, Emeritus Professor and Dr. Pankaj Kr.Roy, Associate Professor of
School of Water Resources Engineering, Jadavpur University for their valuable
suggestions.
I would also express my sincere thanks Mr. Biprodip Mukherjee, Research Scholar of
School of Water Resources Engineering, Jadavpur University for his unconditional
support and affection during my work.
Thanks are also due to all staff of School of Water Resources Engineering and the
Regional Centre, NAEB, Jadavpur University for their help and support.
I am also grateful to my family and my son who have been my strength and
inspiration throughout my M.E. course.
Date : May, 2015
Place : Jadavpur University
SUKANTA MONDAL
(Exam Roll No: M6WRP15-15)
ix
ABSTRACT
This study is on the real life operation of the Prakash Industries Ltd. Situated at Champa,
Chattisgarh, India which is a captive power plant to support an associated steel plant.
CAESAR II software developed by COADE, USA has been used in this study. CAESAR
II is a PC-based pipe stress analysis software package that is developed, marketed and sold
by Intergraph CAS. This software is an engineering tool used in the mechanical design and
analysis of piping systems. CAESAR II is used to create a model of a piping system
represented by simple three dimensional beam elements and to define the loading
conditions imposed on the system.
After giving necessary input data, CAESAR II produces results in the form of
displacements, loads and stresses throughout the system. Additionally, CAESAR II
compares these results to limits specified by recognized codes and standards. As per the
data received the inputs are given and accordingly the results are interpreted in word and
excel format. The whole network of service area is under Prakash Industries Ltd. and it
consists of two waste heat recovery boilers and three turbines.
In this study three dimensional deflections have been sorted out for the nodes of the whole
steam piping system and their characteristics have been discussed. The code stress have
also been matched with stress output reports and discussed. Finally the supports have been
optimistically designed and selected out for the system to keep the deflections and the
stresses under check keeping in view the economical and positioning factor of the
supports. Here to minimise deflections and stresses, about 20 guide supports, 10 free
supports, 10 hangers and 6 anchors were used which are user defined.
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CONTENT
Page no
Declaration
Certificate of Recommendation
Certificate of Approval
Acknowledgement
Abstract
iii
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xi
CHAPTER 1
1.1 Introduction
1.2 Classification of pipe
1.3 Wall thickness
1.4 Schedule
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2
2
CHAPTER 2
2.1 Objective of study
2.2Methodology
3
3
CHAPTER 3
3.1 Historical background
3.2 Review of earlier works
5
5
CHAPTER 4
4.1 Physical components of steam pipeline networks
4.1.1 Flange
4.1.2 Classification of flange
4.2 Valve
4.2.1 Valve selection
4.2.2 Function of valve
4.3 Stresses in steam piping system
4.3.1 Stress
4.3.2 Classification of loads
4.3.3 Classification of stress
4.4 Overview of CAESAR II software
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9
9
11
12
14
14
14
15
16
19
CHAPTER 5
Study area
21
CHAPTER 6
Results & Discussions
23
CHAPTER 7
Conclusion
25
References
Annexure I
Annexure II
26
28
68
xiii
CHAPTER 1
1.1 INTRODUCTION
Pipes are the most delicate component 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. Ignoring
any such load while designing, erecting, hydro-testing, start-up shut-down normal
operation, maintenance etc. 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
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. Identity 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 stress and strain that would be developed in the
crystals/grains of the Material of Construction (MOC) of the piping system.
3. Decide the worst three dimensional stress states that the MOC can withstand without
failure.
4. Get the cumulative effect of all the potential, loads on the three dimensional (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.
1.2 CLASSIFICATION OF PIPE
Based on the method of manufacture, pipes could be classified as:
A. WELDEDPIPE
a) Electric Resistant welded (ERW): Pipes having longitudinal butt joint wherein
coalescence is produced by the heat obtained from resistance of the pipe to flow of
electric current in a circuit of which the pipe is a part and by applicable of
pressure.
1
b) Furnace butt welded, continuous welded: pipes having longitudinal weld joints
forge weld by mechanical pressure developed in passing the hot-formed and edge
heated skelp through round pass weld rolls.
c) Electric Fusion Weld (EFW): Pipes having longitudinal butt joint wherein
coalescence is produced in the preformed tube by manual or automatic electric arc
welding; weld may be single or double.
d) Double Submerged arc welded: pipes having longitudinal butt joint produced by at
least two passes, one of which is on the inside of the pipe. Coalescence is produced
by heating with an electric arc or arcs between the bare metal electrode or
electrode and the pipe. Pressure is not used and filler material is obtained from
electrode.
e) Sprial welded: Pipes having helical seam with either a butt, lap, lock-seam joint
which is welded using either an electric resistance, electric fusion or double
submerged are welding process.
B.SEAMLESS PIPE: Pipes produced by piercing a billet followed by rolling or
drawing or both.
1.3
WALL THICKNESS
Prior to ASME B36.10 AND ASME B 36.19 thickness became effective, the
pipes were manufactured as per the iron pipe standard (IPS) with wall thickness
designations standard weight (STD), extra strong (XS) and Double Extra Strong
(XXS).
Subsequently schedule numbers were added as convenient designations. The pipe
thickness is designated by schedule number and corresponding thickness is
specified in the standard ASME B36.10 for carbon steel pipes and ASME B 36.19
for stainless pipes.
1.4
SCHEDULE
Stainless steel pipes are available in schedule5S, 10S, 40S and 80s whereas
Carbon steel pipe are available in schedule
5, 10, 20, 30, 40, 60, 80, 100, 120, 140, 160, STD, XS, XXS
2
REFERENCES
ASME B36.10M- Welded and Seamless wrought steel pipe
ASME B31.1-2007 Power Piping
ASME M31.3-2008 Process piping
ASME B16.5-2009, Pipe Flange and flange fittings
ASME B16.9-2003, Factory made wrought butt welding fittings
ASME B16.11-2009, Forged fittings, socket-welding and threaded.
ASME B16.21-2005, nonmetallic flat gaskets for pipe flanges
ASME B16.34-2004, Valve S-flanged, threaded, and welding end
Chatterjee, B. (2011). Pipeline transient analysis of Mejia Thermal Power Station, DVC
by HAMMER Software. M.E. Thesis. School of Water Resources Engineering,
Jadavpur University, Kolkata: India.
Das, S. (2006). Study of pipeline network system and temporal decay of chlorine for the
water treatment plant at Dakshin Raipur, West Bengal. M.E. Thesis. School of Water
Resources Engineering, Jadavpur University, Kolkata: India.
Das, S., Roy, P.K. and Mazumdar, A. (2008). Analysis of pipe flow and headloss of a
modeled network based on EPANET in a water treatment plant at Raipur, West
Bengal. Journal of the Institution of Public Health Engineers, India, 2008-09(3), pp.
21-28.
Das S., Mukherjee B. and Mazumdar A. (2013). Analysis of Hammer Head at Increased
Flow Demand in Pipe Networks: A Case Study. International Review of Mechanical
Engineering, 7(4), pp. 757-766.
Jaman H. (2011). Modification of Hunter’s Curve in the Perspective of Water and Energy
Conservation. M.E. Thesis. School of Water Resources Engineering, Jadavpur
University, Kolkata: India.
Mazumdar A., Jaman H. and Das S.(2013). Modification of Hunter's Curve in the
Perspective of Water Conservation. Journal of Pipeline Systems Engineering and
Practice. 5(1), pp. 04013007(1-9). doi: 10.1061/(ASCE)PS.1949-1204.0000150.
Mukherjee, B. (2012). Pipeline design and analysis of distribution network of Dhapa water
treatment plant, KMC by EPANET and HAMMER software. M.E. Thesis. School of
Water Resources Engineering, Jadavpur University, Kolkata: India.
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Mukherjee, B., Das, S. and Mazumdar, A. (2012). Comparison of Pipeline Hydraulic
Analysis between EPANET and HAMMER softwares, International Journal of
Advances in Science and Technology, 4(6), pp. 52-63.
Mukherjee, B., Das, S., Mazumdar, A. and Sarkar, P. (2015). Management in Real time
Operation of Drinking Water pipeline Distribution Network: A case study. 47th
IWWA Annual Convention, pp. 298-303.
Mukherjee, B., Das, S. and Mazumdar, A. (2015). Transient Analysis of a Pipeline
Network for Drinking Purpose in Assam, India. Journal of the Institution of Public
Health Engineers, India 2014-15 (4), pp. 26-32.
Saha, S. (2010). Analysis of pipeline alignment of a Thermal power plant based on
pipeline identification with help of Geoinformatics tools (PIGMI) and HAMMER.
M.E. Thesis. School of Water Resources Engineering, Jadavpur University, Kolkata
Sarkar, P.K. (2014). Extended Period Simulations of Pipeline Distribution Network of
Garfa Boosting Station by Hammer and WaterGEMS Softwares. M.E. Thesis. School
of Water Resources Engineering, Jadavpur University, Kolkata: India.
Smith, P. (2005). Piping materials selection and application, Elsevier, UK
Kannappan, S. (1986). Introduction to Piping Stress Analysis- John Wiley & Sons,
Canada.
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