Limit loads for piping branch junctions under internal pressure and in-plane bending—Extended solutions

The authors have previously proposed plastic limit load solutions for thin-walled branch junctions under internal pressure and in-plane bending, based on finite element (FE) limit loads resulting from three-dimensional (3-D) FE limit analyses using elastic–perfectly plastic materials [Kim YJ, Lee KH, Park CY. Limit loads for thin-walled piping branch junctions under internal pressure and in-plane bending. Int J Press Vessels Piping 2006;83:645–53]. The solutions are valid for ratios of the branch-to-run pipe radius and thickness from 0.4 to 1.0, and for the mean radius-to-thickness ratio of the run pipe from 10.0 to 20.0. Moreover, the solutions considered the case of in-plane bending only on the branch pipe. This paper extends the previous solutions in two aspects. Firstly, plastic limit load solutions are given also for in-plane bending on the run pipe. Secondly, the validity of the proposed solutions is extended to ratios of the branch-to-run pipe radius and thickness from 0.0 to 1.0, and the mean radius-to-thickness ratio of the run pipe from 5.0 to 20.0. Comparisons with FE results show good agreement.     

Limit loads for thin-walled piping branch junctions under internal pressure and in-plane bending

The present work presents plastic limit load solutions for thin-walled branch junctions under internal pressure and in-plane bending, based on detailed three-dimensional (3-D) finite element (FE) limit analyses using elastic–perfectly plastic materials. To assure reliability of the FE limit loads, modelling issues are addressed first, such as the effect of kinematic boundary conditions and branch junction geometries on the FE limit loads. Then the FE limit loads for branch junctions under internal pressure and in-plane bending are compared with existing limit load solutions, and new limit load solutions, improving the accuracy, are proposed based on the FE results. The proposed solutions are valid for ratios of the branch-to-run pipe radius and thickness from 0.4 to 1.0, and the mean radius-to-thickness ratio of the run pipe from 10.0 to 20.0.     

Shakedown and limit analysis of 90° pipe bends under internal pressure,cyclic in-plane bending and cyclic thermal loading

The Linear Matching Method is used to create the shakedown limit and limit load interaction curves of 90° pipe bends for a range of bend factors. Two load cases are considered i) internal pressure and in-plane bending (which includes opening, closing and reversed bending) and ii) internal pressure and a cyclic through wall temperature difference giving rise to thermal stresses. The effects of the ratios of bend radius to pipe mean radius (R/r) and mean radius to wall thickness (r/t) on the limit load and shakedown behaviour are presented.     

Limit and plastic collapse loads for un-reinforced mitred bends under pressure and bending

Approximate limit and plastic collapse load solutions for un-reinforced mitred bends under internal pressure and under bending are proposed in this paper, based on three-dimensional finite element analysis and approximate solutions for smooth bends. Solutions are given for single- and multi-mitred bends (mainly for single and double segmented bends) with the pipe mean radius-to-thickness ratio (r/t) ranging from r/t = 5 to r/t = 50, and the bend radius-to-mean radius ratio (R/r) from R/r = 2 to R/r = 4. Internal pressure, in-plane bending and out-of-plane bending loads are considered, but not their combination. It is found that the essential features of limit and plastic collapse loads for mitred bends are similar to those for smooth bends, and thus existing solutions for smooth elbows can be used to construct limit loads and plastic collapse for mitred bends.     

Limit loads for pipe bends under combined pressure and in-plane bending based on finite element limit analysis

Approximate plastic limit load solutions for pipe bends under combined internal pressure and bending are obtained from detailed three-dimensional (3-D) FE limit analyses based on elastic-perfectly plastic materials with the small geometry change option. The FE results show that existing limit load solutions for pipe bends are lower bounds but can be very different from the present FE results in some cases, particularly for bending. Accordingly closed-form approximations are proposed for pipe bends under combined pressure and in-plane bending based on the FE results.     

Effect of reinforcement on plastic limit loads of branch junctions

This paper provides effects of reinforcement shape and area on plastic limit loads of branch junctions under internal pressure and in-plane/out-of-plane bending, via detailed three-dimensional finite element limit analysis assuming elastic-perfectly plastic material behaviour. It is found that reinforcement is most effective when (in-plane/out-of-plane) bending is applied to the branch pipe. When bending is applied to the run pipe, reinforcement is less effective when bending is applied to the branch pipe. The reinforcement effect is the least effective for internal pressure.     

Effects of attached straight pipes on finite element limit analysis for pipe bends

The effect of the length of an attached straight pipe on the plastic limit load of a 90° pipe bend under combined pressure and bending is quantified, based on finite element (FE) limit analyses using elastic–perfectly plastic materials with the small geometry change option. Systematic FE limit analyses of pipe bends with various lengths of the attached pipe are performed. It is shown that the effect of the length of the attached straight pipe on plastic limit loads can be significant, and the limit loads tend to decrease with decrease of the length of the attached straight pipe. In the limiting case of no attachment, the limit loads are found to be close to existing analytical solutions.     

On the shakedown analysis of welded pipes

This paper presents the shakedown analysis of welded pipes subjected to a constant internal pressure and a varying thermal load. The Linear Matching Method (LMM) is applied to investigate the upper and lower bound shakedown limits of the pipes. Individual effects of i) geometry of weld metal, ii) ratio of inner radius to wall thickness and iii) all material properties of Weld Metal (WM), Heat Affected Zone (HAZ) and Parent Material (PM) on shakedown limits are investigated. The ranges of these variables are chosen to cover the majority of common pipe configurations. Corresponding individual influence functions on the shakedown limits are generated. These are then combined to allow the creation of a safety shakedown envelope, which can be used for the design of any welded pipes within the specified ranges. The effect of temperature-dependent yield stress (in PM, HAZ and WM) on these shakedown limits is also investigated.     

Net-section limit moments and approximate J estimates for circumferential cracks at the interface between elbows and pipes

This paper firstly presents net-section limit moments for circumferential through-wall and part-through surface cracks at the interface between elbows and attached straight pipes under in-plane bending. Closed-form solutions are proposed based on fitting results from small strain FE limit analyses using elastic–perfectly plastic materials. Net-section limit moments for circumferential cracks at the interface between elbows and attached straight pipes are found to be close to those for cracks in the centre of elbows, implying that the location of the circumferential crack within an elbow has a minimal effect on the net-section limit moment. Accordingly it is also found that the assumption that the crack locates in a straight pipe could significantly overestimate the net-section limit load (and thus maximum load-carrying capacity) of the cracked component. Based on the proposed net-section limit moment, a method to estimate elastic–plastic J based on the reference stress approach is proposed for circumferential cracks at the interface between elbows and attached straight pipes under in-plane bending.     

Plastic collapse of pipe bends under combined internal pressure and in-plane bending

Plastic collapse of pipe bends with attached straight pipes under combined internal pressure and in-plane closing moment is investigated by elastic–plastic finite element analysis. Three load histories are investigated, proportional loading, sequential pressure–moment loading and sequential moment–pressure loading. Three categories of ductile failure load are defined: limit load, plastic load (with associated criteria of collapse) and instability loads. The results show that theoretical limit analysis is not conservative for all the load combinations considered. The calculated plastic load is dependent on the plastic collapse criteria used. The plastic instability load gives an objective measure of failure and accounts for the effects of large deformations. The proportional and pressure–moment load cases exhibit significant geometric strengthening, whereas the moment–pressure load case exhibits significant geometric weakening.     

Plastic collapse moment of 90° long radius elbows with internal circumferential surface crack at intrados under in-plane bending

Piping elbows under in-plane bending moment are vulnerable to cracking. The crack initiates at the surface and eventually reaches through the thickness and may lead to failure. The structural integrity assessment requires knowledge of the limit load. Limit load solutions for elbows with through-wall crack configurations are available in the open literature. But solutions for surface crack are not available. This paper presents a closed form expression for the plastic collapse moment (PCM) of 90°, long radius elbows with circumferential surface cracks at the intrados, under in-plane bending moment. The expression is derived, based on the results of non-linear (geometric and material) FE analyses covering a wide range of geometries and crack sizes. These plastic collapse moments evaluated herein will help in structural integrity assessment.     

A comparison of plastic collapse and limit loads for single mitred pipe bends under in-plane bending

This paper presents a comparison of the plastic collapse loads from experimental in-plane bending tests on three 90° single un-reinforced mitred pipe bends, with the results from various 3D solid finite element models. The bending load applied reduced the bend angle and in turn, the resulting cross-sectional ovalisation led to a recognised weakening mechanism. In addition, at maximum load there was a reversal in stiffness, characteristic of buckling. This reversal in stiffness was accompanied by significant ovalisation and plasticity at the mitre intersection. Both the weakening mechanism and the post-buckling behaviour are only observable by testing or by including large displacement effects in the plastic finite element solution. A small displacement limit solution with an elastic-perfectly plastic material model overestimated the collapse load by more than 40% and could not reproduce the buckling behaviour.     

Out-of-plane bending of an elbow or pipe bend under an end-loaded shear force

There are ten unit problems for a 90° elbow subjected to pressure, seismic loads and end loads. The unit problem considered in this paper consists of an end-loaded shear force which produces out-of-plane bending. Equilibrium is maintained at the other end of the elbow by a twisting moment and a bending moment.The methods of toroidal elasticity are used to determine the zero order and first order stress states, the stress field being determined by a converging series. The results are readily generalized to refer to a pipe bend. In addition, the results are applicable by a limit process to a solid circular ring sector.     

Analysis of cyclic creep and rupture. Part 2: calculation of cyclic reference stresses and ratcheting interaction diagrams

Part 1 gives the basis for the use of cyclic reference stresses for high temperature design and assessment. The methodology relies on elastic–plastic calculations for limit loads, ratcheting and shakedown. In this paper we use a commercial non-linear finite element code for these calculations. Two fairly complex and realistic geometries with cyclic loads are analysed, namely a pipe elbow and a traveling thermal shock in a pressurized pipe. The special case of start-up shut-down cycles is also discussed. Creep and rupture predictions may be made from the results. When reference stresses can be economically calculated, their use for high temperature design has the following advantages.

• •Accuracy. Limit loads, shakedown and ratcheting limits are based on detailed analysis, and do not rely on rules or judgement.
• •Efficiency. Use of shakedown and ratcheting reference stresses to predict rupture and creep strain, respectively, allowing details of time and temperature to be dealt with as material data, not affecting the analysis.
• •Factors of safety. For both low and high temperature problems, factors of safety can be determined or applied, based on the real failure boundaries.
• •Conservatism. The rupture and strain calculations reflect the limit of rapid cycle behaviour. Cycles with relaxation will be associated with longer lives.

     

Shakedown and limit analyses for 3-D structures using the linear matching method

A recently developed method for 3-D shakedown and limit analyses is evaluated in the present paper. The shakedown and limit loads of a holed plate subjected to biaxial loading are calculated by implementing the upper bound linear matching method into the commercial FE code ABAQUS. A defective pipeline under the combined action of internal pressure and axial tension is also analysed for both shakedown and limit capacities and the results compared with a standard programming method. All the numerical examples confirm the applicability of this procedure to complex 3-D structures.     

Limit and shakedown analysis of nozzle/cylinder intersections under internal pressure and in-plane moment loading

A simple technique called the elastic compensation method developed previously by Mackenzie & Boyle is used in combination with full three-dimensional finite-element analysis to obtain limit and shakedown interaction diagrams for nozzle/cylinder intersections subject to combined internal pressure and in-plane nozzle moment loading. The results are compared with solutions from the literature and also with detailed elasto-plastic thin shell finite-element analysis. It is found that the simple elastic compensation procedure can provide good estimates of plastic failure mechanisms for complex three-dimensional structures. A detailed discussion of various issues which arose relates to finite-element modelling and the measures taken to improve the results are also documented.     

The interaction of pressure, in-plane moment and torque loadings on piping elbows

This study concerns the load interaction behaviour of 90° smooth piping elbows with circular cross-section and long straight tangent pipes. The finite element method is used for stress analysis of elbows having a wide range of bend and pipe factors. The main aim of the study is to establish the first yield interaction behaviour when an elbow is subjected to a combination loading of in-plane bending, torsion and internal pressure. The study shows that load interaction is influenced by pipe factor, bend radius and load coupling effect, with thinner elbows being affected to a larger degree.     

Analysis and experiments on the plastic limit pressure of elbows

This paper discusses the plastic limit pressure of elbows without defects and with local thinned area in the extrados. Finite element analysis (FEA) and experiments have been used. The results of FEA show that the limit load of elbows under internal pressure increases with increasing wall thickness and bend radius of the elbow. The results are consistent with the calculated results by the Goodall formula, the maximum error is 6.58%. By data fitting of FEA, an empirical formula for the limit load of elbows with local thinned area in the extrados has been proposed, which is validated by experiments.     

Nonlinear analysis and plastic deformation of pipe elbows subjected to in-plane bending

The purpose of this study is to investigate the large strain and stress analysis for pipe elbows subjected to in-plane bending moments. A finite element model for the bend was constructed and loaded taking geometric and material nonlinearities into account using (ABAQUS) nonlinear finite element code. The initiation of yielding for the opening and closing cases appears at the inside surface of the elbow crown. However, further loading causes a significant difference in strain distribution and deformed shapes. The limit moment for the opening cases is higher than that for closing due to the geometric stiffening effects.     

On the shakedown analysis of nozzles using elasto-plastic FEA

The performed shakedown calculations of a dished end with a nozzle in the knuckle region with varying internal pressure load, and two cylinder–cylinder intersections with constant moment load and varying internal pressure load are example cases for the application of the check against progressive plastic deformation as stated in the new European UFPV standard, Annex 5.B: “Direct route for design by analysis” (DBA). To calculate the shakedown limits, Melan's (lower bound) shakedown theorem is used. In this context, the usage of the deviatoric maps of stress states to obtain proper self-equilibrating stress fields is shown. Furthermore, some problems and corresponding possible solutions for performing the shakedown check using a finite element model with shell elements are stated and shown in the examples.