Pipe network flexibility study
Industrial piping networks are subject to significant temperature variations linked to process operating conditions. These variations give rise to thermal expansion and contraction, which can generate significant mechanical stresses within the lines, at support points and at equipment connections.
When these phenomena are not properly taken into account, they can lead to overstressing, excessive deformation, stresses transmitted to the equipment and, ultimately, assembly failure or fracture. The flexibility study aims to analyze these behaviors in order to guarantee the mechanical robustness of the networks under all their loads.
Technical and industrial challenges
Thermal stress is one of the main causes of damage to industrial piping systems. Differential expansion can lead to :
- excessive strain on sensitive equipment connections
- high stresses on substrates
- high stresses on welds and bends
- misalignment or leakage on bolted flanges
These issues concern both new installations and existing networks subject to changes in thermal regime, modernization or changes in operating conditions.
Controlling network flexibility is therefore a key issue in terms of mechanical reliability, safety and compliance with applicable calculation codes.
Scope and approach
SIM Engineering carries out flexibility studies aimed at guaranteeing the mechanical strength of piping networks under the combined effect of thermal, mechanical and environmental loads.
The approach is based on representative modeling of the network, integrating its actual operating and support conditions, in order to accurately assess the stresses and strains transmitted to the equipment.
Taking loads into account
The analysis begins by identifying and integrating the loads applicable to the network. The main loads taken into account include :
- the dead weight of pipes and fittings
- internal and external pressures
- temperature variations and associated thermal gradients
- flow-induced forces
- external forces such as earthquakes or winds
This global approach makes it possible to simulate the most unfavorable conditions and anticipate the maximum stresses likely to affect the network.
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Modeling and calculations
Based on the input data, a calculation model is developed to accurately represent the geometry, mechanical properties and support conditions of the network.
Calculations verify the mechanical stresses in the various sections and ensure that they remain compatible with the admissible limits defined by the applicable codes. Load descent and stress distribution are analyzed to identify how stresses are transmitted to surrounding supports and structures. Particular attention is paid to stresses at device connections, especially on machine nozzles, heat exchangers or sensitive equipment.
Analysis of assemblies and critical zones
Bolted flange joints are subjected to a specific analysis to assess the tensile, flexural and shear stresses likely to affect their tightness and mechanical integrity.
The study can also include a modal analysis of the network to identify natural frequencies and assess the risk of interaction with possible dynamic excitations.A detailed assessment of critical zones and rigid points allows us to detect stress concentrations, excessive stiffness or configurations likely to limit the capacity to absorb thermal expansion.
Results and recommendations
On completion of the calculations, SIM Engineering provides a detailed analysis of the stresses, displacements and forces transmitted to the equipment.
Where exceedances or sensitive areas are identified, technical recommendations are made. These may include :- route optimization to improve flexibility
- modification or repositioning of supports
- addition of expansion absorbers
- adjustment of fixing conditions
- local reinforcement of certain zones
The aim is to optimize stress distribution, limit the forces transmitted to the devices, and prevent failure due to thermal variations or external forces.
- route optimization to improve flexibility
Flexibility engineering for plant sustainability
The flexibility study is an essential step in securing piping networks subject to thermal variations and complex loads.
By combining rigorous modeling, stress analysis and field expertise, SIM Engineering supports its customers in the design and optimization of mechanically robust networks.This approach guarantees the durability of installations, preserves the integrity of connected equipment, and ensures that industrial projects are based on long-term performance and sustainability.
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