Pipe Stress Analysis Services:
With its expertise in piping systems, IGES offers Pipe Stress
Analysis Services and Pipe Support Engineering to its clients. This service
caters to the requirements of both Process Power, and District Cooling Piping
Systems
Pipe Stress Analysis
Pipe Flexibility is a critical component in any piping
design. It is mandatory that the critical piping which are operating under high
pressure or high temperature services need to be analyzed for flexibility ,
expansion and load sustaining capabilities. Apart from process and power
piping, District cooling systems which employ pre-insulated pipes and piping
inside the energy transfer stations need to be analyzed for flexibility and
expansion as per ASME B31.3 code. InfoGrafix offers comprehensive service which
covers all aspects of Pipe Stress analysis in both industries.
Pipe Stress Analysis for Onshore and off shore Process and
Power Piping :
Determining the maximum flow capacity of a system (e.g.
ship/ shore cargo transfer).
Advising on pipeline routing and elevation profile.
Static load and stress calculations of above ground and
underground piping systems
Wind load calculation
FRP & GRP pipe stress analysis
Offshore piping stress analysis
Fatigue analysis and cumulative usage report
Dynamic analysis and harmonic forces and displacements of
piping systems
Mode shapes and natural frequency calculations
Shock spectrum analysis and independent support motion
(earthquake)
Force spectrum analysis (liquid hammer, slug flow &
relief valve discharge)
Model time history analysis
Calculation of Spring Stiffness
Thrust force of Expansion Bellows
Effects of Thermal Loads, Occasional loads such as Hydrostatic Test, Safety Valve's Reaction Force, Seismic Loads, Wind Loads
Safety Valve Reaction Force
Calculation of Displacement of Terminal point movement due
to Thermal, Equipment Foundation Settlement ,Pipe Support Movement, Pipe
Support Foundation Settlement
Pipe Stress Analysis for Onshore and off shore Process and
Power Piping :
The purpose of the stress analysis in Chilled water Network
lines is to identify the behavior of the Chilled water pipes under the
potential static loading experienced from the start up to operation. In particular,
the stress analysis is undertaken to confirm that stresses produced in the
network as a result of the temperature difference, pressure and dead weight
will comply with the governing codes for such static loads. Moreover, the
calculated displacements and restraint (anchors and hangers) loads under these
static conditions should comply as well with these governing codes.
Due to the extensive calculations required, the stress
analysis will be carried out with the assistance of computer simulation and
modeling software.
The stress analysis provides useful design information
including the location of any high stress concentrations and bends within the
network it also highlights areas requiring attention by way of redesign and or
adding additional anchors or hangers to eliminate high stresses in the network
piping.
As a service to the new industry IGES provides comprehensive
service which includes :
Static load and stress calculations of above ground and
underground piping systems
Calculation of Insulation density
Wind load calculation
FRP & GRP pipe stress analysis
Fatigue analysis
Calculation of Spring Stiffness
Thrust force of Expansion Bellows
Effects of Thermal Loads, Occasional loads such as
Hydrostatic Test, Safety Valve's Reaction Force, Seismic Loads, Wind Loads.
Vibration Analysis
Steam Hammer & Water Hammer
Calculation of Displacement of Terminal point movement due to
Thermal, Equipment Foundation Settlement ,Pipe Support Movement, Pipe Support
Foundation Settlement
Pipe Support Engineering Design:
Selection of Pipe Supports
Load calculation for Pipe Support
Structural design of Pipe Supports
Spring Hanger Data Sheets
Thrust Block Sizing
Plates, Inserts & Loading
Drawing (input to Civil)
Root Cause Analysis:
IGES team can visit the site and collect necessary
information and accordingly analyze the problem analytically considering design
aspects (Critical, Logical, Stress Analysis, etc) and provide recommendations
for any piping modifications so as to overcome the prevailing piping related
problems.
Typical problems may be :
Compressed Air Flow Analysis: Inadequate flow of plant
air, instrument Air to the user points.
Water Flow Analysis: Inadequate flow of cooling water,
Service water, potable water, etc to the user points.
HVAC Calculations: Inadequate suction of toxic fumes
from originating points
Expansion Joint Failure: due to improper pipe support
design.
Pipe Support/ Spring Support failure.
Excessive Vibration: Suspected to be due to rigid or
poor piping design.
Piping Flange Joint Leakage: This may be due to
improper Pipe support design.
Fluid Flow Dynamics Services:
IGES can offer advice in designing the hydraulic system to be
more optimized to its purpose, to improve its safety and to cost less money.
Typically the services include:
Determining the maximum flow capacity of a system (e.g.
ship/ shore cargo transfer).
Advising on pipeline routing and elevation profile.
Optimizing the pipe diameter by calculating flow, pressure
and velocity of fluid in the pipeline.
Optimizing the Pump Size by calculating pumping costs vs.
pipeline diameter for typical pipe materials.
Specifying surge suppression equipment to improve both the
peak pressures and the overall operability of the pipeline. For example,
determining the check valve size, type and dynamic performance needed to
prevent check valve slam. Or specifying the best location for air valves and
their sizing.
Surge Analysis Services:
IGES is a regional leader in surge analysis and dynamic
simulation. Have performed services for all the major oil companies and
consultants in the
This service is performed using Sunrise Systems PIPENET
Software. PIPENET is a leader in Fluid Flow analysis and is being used and
approved by leading consultants, Owner operators worldwide. Its not just the
software which makes our service the best, but also The projects are handled by
highly experienced consultants who carry a wealth of many years of similar
experience.
Every study provides the simulation results with our
observations, scenarios, recommendations and conclusions, thus our
recommendations are of an independent company who offers unbiased advice on
design and equipment selection.
Simulation and surge analysis give a wide range of benefits during design and operation. Once the computer models are built they can be used throughout a project's life.
Typical Applications of Surge Analysis are :
Tanker Loading Systems
The loading and unloading of tankers with petrochemical fluid
ranging from crude oil to liquefied natural gas is a happening every moment
throughout the world. However, it is an operation associated with the dangers
of spillage, fire, explosion as well as the fury of the sea.
The design of a ship transfer facility is usually a
compromise of loading times (demurrage) and construction cost. The overall
combination of high flow rates, relatively short distances coupled with
intermittent operation lead to high velocities. IMO regulations require
transfer flow to be stopped rapidly in the event of any emergency, which
usually means valve closures of less than 30s and the generation of high and
rapidly applied surge pressures. Experience has shown that the potential for
damage to pipework and hoses, spillage and failure of equipment can be easily
realized
Firewater Systems
Firewater systems are essential to the safety of many areas
within the oil, gas and petrochemicals industry. Due to the requirement to
rapidly deliver large volumes of water to a specific area, high water
velocities are often experienced, which in turn can lead to large surge
pressures, both on start-up and shutdown
Cooling Water Systems
The transfer of heat to and from process fluids is critical
to the operation of most process plants. Cooling medium systems and heating
medium systems are generally robust but there are a number of problems which
can occur if these systems are not designed carefully, Such as Buckling of underground
piping due to sub-atmospheric pressures following a 'low pressure' event such
as trip of one or more pumps, Full vacuum in the highest elevation heat
exchangers following pump trip, Excessive surge pressures when the pump is
restarted and the vapour pockets collapsed and Surge pressures in excess of the
piping design pressure, caused by:
Emergency shutdown of a heat exchanger
Rupture of a heat exchanger tube
Pump trip and pump start-up
Check valve slam and Fatigue failure caused by high piping
vibration or excessive piping loads.
Mechanical (Static Equipment) Design Services
InfoGrafix performs analysis and design on most horizontal
and vertical towers, vessel, storage tank and heat exchanger configurations
refineries, chemical plants, power plants, nuclear plants and other processing
facilities to check or ensure compliance with ASME VIII, TEMA and API design
codes.
Pressure Vessels:
Typical design / Analysis services provided on pressure
vessels are as below:
Design and analysis of Pressure Vessels (Tall Columns,
Vertical Pressure Vessels, Horizontal Pressure Vessels, Spherical Vessels,
Reactors etc.) based on ASMEBoiler & Pressure Vessel Code, Section VIII,
Div. - 1, Div. - 2 and Div. - 3.
Analysis of Power Boilers per ASME Boiler & Pressure
Vessel Code, Section-1.
Calculations for repair and alteration of existing Pressure
Vessels per API-510 and National Board Inspection Code.
Calculation of minimum retirement thickness values for
existing pressure vessels / pressure vessel components to maximize the
remaining safe and useful life.
Re-rating of pressure vessels for a new set of design
parameters.
Calculations to check the suitability of vessels for in-situ
PWHT.
Fitness-for-service evaluations for pressure vessels to
assure the structural integrity of equipment for the intended design parameters
and to offer life extension considerations.
Fatigue analysis to calculate the fatigue life of pressure
vessels subjected to pressure cycles, temperature cycles and startup / shutdown
cycles.
Failure Analysis to identify the root cause of failure for
the failed pressure vessels or pressure vessel components.
Finite Element Analysis for pressure vessels and pressure
vessel components.
Heat Exchangers:
Typical Design / Analysis services provided on Heat
Exchangers are as below:
Design and analysis of Heat Exchangers based on TEMA and
ASME Boiler & Pressure Vessel Code, Section VIII, Div. - 1.
Calculation of minimum retirement thickness values for
existing heat exchangers / heat exchanger components to maximize the remaining
safe and useful life.
Calculations for repair and alteration of existing heat
exchangers.
Calculations for tubesheet thicknesses for various type of
heat exchangers.
Calculations for other heat exchanger components e.g.
Channel covers, floating heads etc.
Calculations for Fixed tubesheet heat exchangers (with or
without flanged and fluid expansion joints) for re-rating and fitness-for-service
evaluation.
Fitness-for-service evaluation of Heat exchangers to
calculate Minimum safe operating temperature (MSOT) for existing heat
exchangers which do not meet the current MDMT requirement of the ASME code.
Re-rating of heat exchangers for a new set of design
parameters.
Fitness-for-service evaluations for heat exchangers to
assure the structural integrity of equipment for the intended design parameters
and to offer life extension considerations.
Fatigue analysis to calculate the fatigue life of heat
exchangers subjected to pressure cycles, temperature cycles and startup /
shutdown cycles.
Structural Engineering /
Analysis:
IGES offers services in Structural engineering / analysis of
structural components used in refineries, chemical plants, power plants,
pharmaceutical plants, food processing plants and other processing facilities.
Typical structural engineering / analysis which are provided are as follows:
Structural engineering calculations per AISC (American
Institute of Steel Construction), IS, ACI, AASHTO, BS, UBC & API to design,
analyze and check the load carrying capacities of various structural components
(vessel internal components, rectangular ducts with stiffeners, pipe racks,
pipe supports, beams, columns, structural connections etc.).
Calculations of minimum retirement thickness based on
structural engineering considerations (also known as structural Min"T") to avoid jeopardizing the structural stability of pressure equipment (Pressure vessels, Heat exchangers,
tanks and piping).
Structural Analysis and Design of special structures and
non-pressure parts (e.g. platforms, ladders, clips and other attachments)
attached to various parts of Pressure Vessels and Heat Exchangers. These
calculations may include hand calculations or customized MathCAD calculations.
Structural stability analysis (e.g. nonlinear buckling
analysis) to make sure that the structure / mechanical component will not
buckle for the given design loading.
Finite Element Analysis
IGES is able to offer a local stress analysis service (at
structural discontinuities) to assess the effects of external loads from piping
on nozzles, heads, and shells.
This can take the form of comparisons with established
empirical methods such as WRC 107/297 or PD 5500 Annex G, or a more accurate
and potentially material saving Finite Element Analysis (FEA). NozzlePRO is
used to perform FEA on nozzles and automatically compare stress levels with the
requirements of ASME VIII Div 2.
We can also provide invaluable information such as:
Nozzle flexibilities
Stress intensification factors
allowable nozzle loads
Industrial Power System Design
IGES can assist in determining the power system requirements,
review current system capacity, and design a solution with proper electric
distribution equipment to in accordance with IEC, IEEE, NEC, NEMA, BS IS and
other International standards.
We perform design and detailed engineering for various types
of electrical systems used in substations, control room, gathering stations,
shipping stations, compressor buildings, process area, utility areas, fire
water pump station buildings, tank farm area, cooling tower system, condensate
units, slug catcher area, pig launcher stations and flare area etc. providing
the following details.
Load flow studies
Relay coordination
Dynamic Analysis
Selection of HV/LV switchgear, motor control centers
Selection of AC/DC UPS
Substation Grounding
Selection of power / distribution transformers
Selection of electrical equipments in hazardous area
Designing supply change over schemes for incoming and
outgoing feeder control schemes
Selection of feeder /motor / transformer protection relays
Power and control cable schedules and cable drum schedules
Interface activities with civil / machinery /
instrumentation
Electrical data input for packaged equipments
Specifications for HV/LV switchgear, motor control centre,
MV/LV motors, power / distribution transformers, lighting / small power
distribution boards, AC / DC UPS, lighting fixtures, power / control cables,
cable trays, earthing materials, etc.
Database customization
Preparation of equipment general arrangement drawings
Preparation of key plan
Performing piping studies
Preparation of critical line list for stress Analysis
Preparation of single line structure drawings and piping
load data
Preparation of nozzle orientation and support cleat
requirement drawings
Preparation of technical specifications for piping and
specialty Items As-built documentation
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