Pipe Stress Analysis Services:
With Its expertise in piping systems, ImageGrafix 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. ImageGrafix 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
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.
Vibration Analysis
Steam Hammer & Water Hammer
Sea Wave load spectrum
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 loadings 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 becarried 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 ImageGrafix 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
ImageGrafix 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
ImageGrafix is a regional leader in surge analysis and dynamic simulation. Have performed services for all the major oil companies and consultants in the Middle East region.
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
ImageGrafix 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 ASME Boiler & 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 flued 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:
ImageGrafix 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
ImageGrafix 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
ImageGrafix power systems group 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
Supports Design
Pipe support engineering including special supports preparation
Preparation of data sheets and requisition for spring hangers, expansion joints, snubbers, slide plates, etc
Pipe Support Layouts
Pipe Support Detail Drawings
Pipe Support Markings based on industry standards and special requirements Standardization of Pipe Supports
Mechanical Detailing (Static Equipment)
Preparation of design basis and standard drawings
Equipment layout drawings, equipment list and nozzles schedules
Equipment foundation drawings, including concrete details
Storage tank fabrication drawings
Bill of materials
Equipment fabrication/shop drawings
Preparation of technical specifications
Preparation of design Calculations
Preparation of data sheets for mechanical equipments
Preparation of requisition for mechanical equipments – for enquiry and order Preparation of fabrication drawings and materials
Structural Detailing
ImageGrafix Software FZCO provides Structural detailing services in accordance with International Standards like, AISC, IS ,ACI, AASHTO, BS, UBC & API.
Steel Detailing Services
Preparation of Basic design calculations and standard drawings
Preparation of 3D structural models using PDMS, SMARTPLANT , CADWorx
Preparation of Steel General Arrangement drawings
Preparation on COG and Bill of Material
Preparation of single line structure drawings and piping load data
Preparation of detailed execution drawings
Preparation of bar bending schedules
Preparation of fabrication / shop drawings
As-built documentation
Civil Detailing Services
Preparation of detailed drawings, Bill of materials and bar bending
schedules for:
Reinforced concrete framed structures
Pile and conventional foundations
Equipment and machinery foundations drawings
Concrete storage silos, large diameter storage tank foundations
Cable and pipe trenches and tunnels
Roads, pavements, grading plan and drainage systems
Gates, compound walls and fencings
Civil Detailing Services
ImageGrafix Software FZCO offers Electrical & Instrumentation Engineering Services which includes preparation of:
Electrical
Single Line Diagrams
PLC Diagrams
Ladder Diagrams
Control Panel drawings
Power Distribution Drawings
Grounding drawing
Cable Schedule
Cassette Design
Cable Trench Drawing
Switchyard / transformer layouts
Switchgear / MCC room / battery room layout
Cable tray / trench layouts
Cable routing/ earthing layouts
Lighting (indoor/outdoor) layouts
Lightning protection layouts
Preparation of interconnection diagrams between different equipments
Preparation of construction scope of work and answer
bidder technical queries
As-built the project drawings / documentation
Bill of quantities for bulk materials
Standard installation drawings for power system, earthing system, lighting system and cable tray/ladders
Instrumentation
Instrument index
Control philosophy
Instrument elevation plan
Instrument hook up drawings
Interlock logic diagrams
Cable tray / cable trench layouts
Detailed execution drawings
Junction box termination drawings
Cable schedules
Fire and gas drawings
Cause and effect drawings
Requisition and specifications for instruments
Foundation field bus installation drawings
