Lecture Notes Part 1 EN v331 Rev 0

ROHR2
Piping analysis part 1

English version
Mikael Lauth
Copyright Skios AB, 2021. Rohr2 Part 1 training for Arvind Rai, 2021-03-22
Agenda
 Introduction  Results evaluation

 Historical background
 Introduction to FEM method
 Secondary steel
 Working with ROHR2  Workshop 4, secondary steel
 Workshop 1, basic modelling

 Piping components
 Loadings  Workshop 5, flange analysis
 Workshop 6, nozzle analysis
 Support types
 Buried piping, information
 Workshop 2, rigid body motion
 Workshop 3, pipe – pipe contact
 Isometry and fesu module
 Code evaluation
 Mandatory workshop 7, real life model
 EN13480
Web based training
 All lectures are given via a Teams meeting
 Workshops are presented and important

notes are given by the teacher
 Pupils will do the workshops by themselves.

 In case of questions or need for help, pupils will
contact the teacher via phone, e-mail etc.
 Next lecture will start with comments and

discussion on previous workshop
History behind pressure vessel codes
 US civil war lasted between 1861 – 1865
 The industrialization increased a lot after the war
 10 000 boiler explosions in North Amerika 1865-1905
 Big accident in Massachusetts 1905 - 58 dead
The R. B. Grover & Company Shoe Factory Boiler Explosion March 20, 1905
One of the greatest disasters in Brockton's history happened on the morning of March 20, 1905. At about 8:00 AM there were around
400 employees at the R. B. Grover & Company shoe factory in Campello when the boiler exploded, shot through the roof and caused
the building to collapse. The boiler traveled several hundred feet, damaging a number of buildings and coming to rest in the wall of
a house.
Escaping gas fueled an intense fire that engulfed the shattered building. Fifty-eight people were killed and 150 were injured.
Källa: http://www.rootsweb.com/~macbrock/boiler.html
 1907 – the first pressure vessel code in Massachusetts
 1911 – the first ASME code
 1949 – the first Swedish pressure vessel code (TKN)
 1955 – the first piping code in USA (B31.1)
 1967 – the first Swedish piping code (RN67)
 1972 – the first regulatory inspection requirements
 2002 – since June 1st, EN13480 is used within EU
 2017 – revision of EN13480
Introduction to FEM
Overview of FEM
Terminology
Solution method
Common mistakes and pitfalls
Introduction to FEM
Four phases:
1. Discretization
2. Analysis of the Elements
3. Analysis of the System
4. Calculation of stresses
This is valid for linear FEM based on the displacement

method
Discretization I
Discretisation means to divide the structure into
smaller regions
Key words:
 Node points
 Elements
 (for ex. pipe, beam, bend, valve)
 Degrees of Freedom (DOF), translation and

rotation
Extra for piping elements in ROHR2:

 Addition of internal pressure
Discretization II
Division of the structure into smaller regions is made with respect to:
 Material properties (usually constant within an element)
 Geometry
 Loads (transfers to nodes in the FEM-model) Beam theory is valid

when the piping model
 Boundary condition fulfills the requirement:
 Displacement function used in element types (3rd order
polynomial function for beams and pipesgives theoretical
exact answer according to Euler-Bernoulli beam theory)
Element analysis
Element analysis:
 Calculation of stiffness properties

 Determine the stiffness properties for each element
Q (N/m) Q x L/2 Q x L/2

 Transformation of distributed loads to nodal loads.
 Distributed , like gravity, are transformed to equivalent
nodal loads. L
Analysis process above is based on material data, geometry, loads,

supports and elements shape functions.
System analysis
System analysis:
Calculation of the displacement field for the total
structure
1. Create stiffness matrices and load vectors [K], {F}

Spring rate, K
2. Modify with respect to elastic supports and linear
dependence
Deformation, d
3. Calculate the displacement field,
see Hooke's law: F= K x d → d=F/K Force, F
Stress analysis
Calculation of stresses:
Displacements from given loads are calculated as:

d=F/K
Stresses for each element is retrieved using displacements,
derivatives and constitutive laws , e=dL/L0, sb= M/Ww
(s = E × e ; Stress = Young’s modulus × Strain)
System matrix
Example of a stiffness matrix:
Local stiffness matrix for a straight,
prismatic beam. Axial force
L
Lateral force
L
N3 N9
N2 N8
N6 N12
N5 N11
z
y N4 N1
L N10 N7
Summary: 4 Phases
1. Discretization
(Splitting model into pipe, bend, valve etc.)
2. Element analysis -> k

(Calculation of stiffness properties and transformation of distributed loads to
equivalent nodal loads)
3. Assembling element matrices to global stiffness matrix-> K

(Calculation of the unknow degrees of freedom)
4. Calculation of stresses and results evaluation against codes
Solution method
INPUT DATA Geometry, Topology, Material properties,
Loading, Supports
Element stiffness matrix, Loop

through all
Stress matrix, nodal loads from elements
line-, surface- and volume loads
Loop
Iterate for non linear solution
Additions to structural equations through all
elements
Solving the equation system

Loop
Element forces och stress through all
elements
Deformation
Stress
Results
Common mistakes and pitfalls
Mistakes in modelling
 Transformation from 3D-continium model to beam model
smax ?
 Uncertainties in input data:
 Geometry
 Loading & Types of supports
 Material properties
Mistakes in Discretization
 Choosing the right element shape function (Not applicable here)
Eg. Branch connection is modelled
 Element size and distribution as a single point on main run
 The elements description of the geometry
SIF
Manipulation error
 Errors in input data (e.g. too few significant digits)
 Truncations errors
 Roundoff errors
Comments
 In ROHR2 (static) we get the exact beam solution and are not F
effected by the FEM-errors (provided equally distributed loads)
 Local phenomena cannot not be considered since the beam

theory assumes no changes of the beam cross section, BUT:
 FESU-module (add-on license) can study local phenomena
 In FEM (also in ROHR2) you either know the load or the

displacement
Working with ROHR2
ROHR2 – Graphical User Interface (GUI)
Title bar
Menu bar
Automatic
search for
updates during Toolbars
Toolbar mode
ROHR2 start up loadings
Toolbars for
supports &
components
Current Output window Overall view

calc.
Toolbars
File new Save Print preview
File open Print Calculate
Project directory
Selecting the current dimension
UNDO Transfer segment data Dimensions of jacket pipes
REDO Create Substructures Dimensions of structural sections
Draw Insert Substructures Line description

Dimensions Setting properties
Node properties
Copy Measure window
Delete
Paste Help Display parameters Segment properties
Move
Select Pipe dimensions

Segment properties Listing
You can toggle the display of the pipe dimensions using the button Dimensions
Toolbars
Rigid support Rigid hanger Damper

Zoom window
Spring support Spring hanger Visco damper
Zoom in
Constant support Constant hanger Shock absorber
Zoom out
Angulating support External flexibility matrix
Reduce scale to system limits Coordinate system 1 XY-view
Coordinate system 2 ZX- view

Save current view
Coordinate system 3 ZY- view
Create default views
Coordinate system 4
Select view
Node Nozzle Nonlinear soil restraint

Flex coupling Stiffness matrix
Point mass Line bedding Additional results
Coupling
Toolbars
Bend Valve Lateral expansion joint Showing the current load case
Flange Angle valve Angular expansion joint

ROHR2 tasks Wind load Initial stressing force
Reducer 3-way valve Axial expansion joint
Tee 4-way valve Blind flange Operation data Snow load Initial support load
Head Anchor point movement Ice load Dynamic fluid hammer
concentrated load
Cold springing Line load Dynamic line load
Point load Spectra combinations
Insert text
Text for result items Result settings Enlarge View Output file
Animation Reduce Output file spring design

Insert picture
Displacement scaling factor
Modelling of piping systems
1. Begin with drawing the main pipeline

 Select to start draw your pipeline
 Use input window to introduce new pipe sections.
 Bends are created automatically
2. Insert supports, components,

branches, etc.
Workshop 1
 Basic modelling
Pipe dimensions
 Enter outer diameter and thickness
manually or from standard
 Mill tolerance and corrosion allowance
 Calculation data
 Calculation pressure Pc – used in the ”internal pressure
analysis” for the pipe dimension and for stress evaluation
according to piping code
 Calculation temperature Tc – used to calculate allowable
stresses, both in the ”internal pressure analysis” for the
pipe dimension and for stress evaluation according to
piping code
Material
 Choose from built-in library

 Define your own from within Materials
Loadings
 Operating load cases with temperature/pressure combinations

 Dead Load
 Gravity (pipe, insulation, medium, etc.) + pressure + force controlled loading
 Operation
 Gravity (pipe, insulation, medium, etc.) + pressure + force controlled loading + temperature
 Shutdown
 Gravity (pipe, insulation, medium, etc.) + pressure + force controlled loading + temperature.
To account for friction forces direction change when pipes cool down.
 Wind loads
 Snow loads
 Ice loads
Loadings
 Line loads
F (N) No cold springing
 Point loads
Fall
 Cold springing
 Used to reduce forces at anchors. Cannot be used to Time
reduce stresses -Fall
Cold springing
 Anchor point movements
Boundary conditions / supports
 Rigid support
 Choose predefined Support type or fix degrees of freedoms
under Components
 Stiffness can be entered. Infinitely stiff is default for Anchor point
 Friction and gap can be entered (except for Anchor Point)
 Internal support allow for coupling against other piping
components or beams.
 Rigid support
 Sliding support
 Guide
 Rigid support
 Sliding + guide support
 Anchor
 Spring hanger
 Automatic design of hangers
 Manual input of spring rate and load
 Internal hanger connects the hanger to other
piping components
 Constant hanger
Special hanger design to take larger
vertical movement with minimal change
in support load
 Rigid hanger
Rigid or flexible link with ball joints at both ends.
Acting in vertical direction only
 Angulating support
 Rigid or flexible link, spring hanger or damper with ball
joints at both ends. Acting in any direction
 Spring support
 Spring support acting from below
 Constant support
 Same as constant hanger, but acting from below
 Rigid support
 Axial stop
The arrangement in the picture to

the right generate an axial
restraint primarily to prevent
movement to the left.
 Note that all rotational and lateral
degrees of freedom are unrestrained
Workshop 2
 Rigid body motion
Segment’s properties
 Easy validation of input
 Provide a mean to select

portions of piping based on
pipe dimensions, loadings,
materials etc.
Analysis settings – ROHR2 tasks
Menu row Loads > Tasks or
-button in the toolbar
 Load cases
 Define load cases with settings
 Superpositions
 Load cases combinations for forces and
moments
 Stress analysis
 Specify code for stress evaluation
Analysis settings – ROHR2 tasks
 Stress analysis
Settings for stress analysis –
standard, number of load cycles,
load case combinations, etc.
Workshop 3
 Pipe-pipe contact
Code evaluation ROHR2
Piping codes
In most countries, calculation standards for pipe systems are seen as recommendations
for how a system is to be calculated. The standard only specifies a minimum level to be
met with respect to personal safety. This means that neither the standard nor the
approval institution guarantees that the pipeline after inspection and approval does not
fail during operation.
Anyone who designs a pipe system may use any calculation method, as long as it can
be proved that the system can withstand applied loads with the corresponding degree
of safety according to the standard. In practice, however, it is easiest to follow the
instructions in the standards to quickly get a piping approved (where approval is
required).
Some countries lack their own national pipeline standards (e.g. England and Germany).
After 1 June 2002, EN13480 combined with strict manufacturer responsibility is used.
We will only cover the European piping standard EN13480.
Strength calculations
1. Dimensioning calculations to be done before ROHR2

calculations
Determine the dimensions for the components (e.g. wall
thickness). See chapter 6 to 9 in EN13480. Internal pressure
analysis in ROHR2 can be used to check the dimensions
2. Stress analysis using ROHR2

Adapt and support the piping system in such way that the
individual components can “withstand” the loads and load
combinations the system is expected to be exposed to. See
chapter 12 in EN13480. This is where ROHR2 should be used.
Strength calculations, internal pressure 1
Hoop (tangential) stress: Length of pipe run is L (mm)
Thin wall pipe having an average diameter of
dm= di + t (mm)
Internal pressure is P (MPa)
t Static equilibrium in vertical direction:

di P
P x dm x L – 2 x F = 0 (1)
P
F Stress over pipe wall thickness is st=F/A
F
F= st x A, A= t x L (2) & (3)
P x dm x L = 2 x st x t x L
st = (P x dm )/ (2 x t )
Strength calculations, internal pressure 2
Axial stress: Thin wall pipe having an average diameter of
t dm= di + t (mm)
Internal pressure is P (MPa)
P di
Static equilibrium in horizontal direction :
P x (dm /2)2 x p – F =0 (4)
Axial stress over pipe wall is sa=F/A

F=sa x A, A= p x dm x t (5) & (6)
F
P x (dm /2)2 x p = sa x p x dm x t
sa = (P x dm )/ (4 x t )
Note that the axial stress is half of the hoop stress

EN13480
 “The standard is in line with the US pipeline standard ANSI B31.1 -

1977 Power Piping.
 The method is intended to be applied to normally suspended pipes and

may not be used for pipelines in which high axial membrane stress may
occur.
 Such stress occurs in, for example, hot water pipes buried directly in soil, because
the friction between surrounding soil and pipes counteracts movement in the axial
direction”.
 The calculation formulas do not take into account for buckling/instability.
EN13480
The calculation method in EN13480 is based on a

number of tests taken into account:
 Force controlled loadings
 Displacement controlled loadings
 ”Shake down” criteria
 Fatigue Material and geometry
 Stress concentrations
EN13480 - Max allowable stress
Force controlled loading
Force controlled loads due to normal operating conditions:
𝑖𝑄𝑋 ×𝑄𝑥𝐴 0,75×𝑖×𝑀𝐴

𝑆1 = s1 = + ≤ 𝑓𝑓
𝐴𝑐 𝑍𝑐
Equation (12.3.2-1)
𝑝𝑐 × 𝜋 × 𝑑𝑖2
𝑄𝑥𝐴 = 𝑚𝑎𝑥 𝑄𝑥𝑆 , + 𝑄𝑥𝑆
4
Note that table H3 have different SIF-values (i) for in- and out of plane bending for bends and branch
connections (ii och io).
Force controlled loading
For normal and temporary force-controlled loading (wind, earthquake,
safety valve release etc.)
𝑖 ×𝑄𝑥 0,75×𝑖×𝑀𝐴 0,75×𝑖×𝑀𝐵

𝑆2 = s2 = 𝑄𝑋 + + ≤ 𝑘 × 𝑓𝑓
𝐴𝑐 𝑍𝑐 𝑍𝑐 Equation (12.3.3-1)
𝑝𝑐 × 𝜋 × 𝑑𝑖2
𝑄𝑥 = 𝑚𝑎𝑥 𝑄𝑥𝐴 + 𝑄𝑥𝐵 , + 𝑄𝑥𝐵 + 𝑄𝑥𝐵
4
k= 1 if the occasional load is acting for more than 10% in any 24h operation period, e.g. normal snow, normal wind.
k= 1,15 if the occasional load is acting for less than 10% in any 24h operation period.
k= 1,2 if the occasional load is acting for less than 1% in any 24h operation period, e.g. dynamic loadings due to valve closing, design basis earthquake;
k= 1,3 for exceptional loads with very low probability e.g. very heavy snow/wind (i.e. =1.75* normal).
k= 1,8 for safe shut-down earthquake
Displacement controlled loading
iQC ×QxC i×MC Equation (12.3.4-1)

S3 = s3 = + ≤ fa
A Z
QxC= Range of axial force due to thermal expansion
Formula (12.3.4-1) May be replaced by:
Equation (12.3.4-2)
S4=s4=s1 + s3 ≤ ff + fa
Displacement controlled loading
Condition when metal temperature is within creep regime:
𝑖𝑄𝐶 ×𝑄𝑥𝐶 0,75×𝑖×𝑀𝐶

𝑆5 = s5 = s1 + + ≤ 𝑓𝐶𝑅 Equation (12.3.5-1)
3×𝐴 3×𝑍
Criterion due to settlement or single occurence events:
𝑖𝑄𝐷 ×𝑄𝑥𝐷 𝑖×𝑀𝐷

𝑆6 = s6 = + ≤ 𝑓𝐷 Equation (12.3.6-1)
𝐴 𝑍
QxD= Axial force due to single occurence event
Stress evaluation
• A summary appears after the

calculations are finished
• Double click on a message
for further information
Everything is alright. The calculation runs without any mistakes
General system information

Error messages. a problem occurs:
The calculation result is totally missing or it is not recommended
to use the result (e.g. the calculation did not use the required
analysis accuracy)
Warnings, Check the results!
Stress evaluation
Load case results
Stress evaluation
Stress analysis
Secondary steel
 Define beam cross sections

in Edit > Dimensions of
structural sections or -
button
 Select beam cross section

from data base or create a
custom section
 A rigid section is defined by
default (_RIGID_)
Secondary steel
 Choose the structural steel dimension

from the toolbar and draw the
structure using
 Insert boundary conditions as usual
 Connect the structure to the piping

system using e.g. an Internal support,
see workshop Pipe-pipe contact
Sekundärstål
Stress evaluation of secondary
steel
 Define a new stress analysis in
ROHR2 Tasks
 Select VGLSP - Equivalent

stresses SIG-V as evaluation
code
 Stress evaluation according to

EN1993, EN13480 or DIN18800
 No stability checks for members

in compression are made in
Rohr2.
Secondary steel
Stresses in
secondary steel
Workshop 4
 Secondary steel:
pipe support
Piping components
 Flanges
 Choose from standard or enter length and mass (for the pair)
manually
 Reducer
 Concentric or eccentric according to standard or manual input
 Tees
 Unreinforced fabricated tee is automatically introduced at a branch
connection. It is possible to insert tees according to standards
 Valves
 Define nominal pressure, length, mass and if flanges should be
inserted
Flange connections
 Automatic evaluation of all load cases
according to:
 EN 1591-1:2014 (2011 & prEN 1591-2020)
 ASME VIII, Div.1:2010
 ASME III, Div. 1, App XI 2007
 Simple pre-setting's for flange properties

– values according to standard for
flanges, bolts and gaskets
 Automatic report generation
Flange connections
 Start the evaluation from within

ROHR2 tasks ( -button)
 The load cases Assembly and

Pressure test needs to be defined
Workshop 5
 Flanges
Teacher:
Show demo on how to make an
expansion loop.
Piping components
Compensators
 Axial bellows – Axial expansion joint
(Note! Be careful when inserting
bellows. It is easy to get it wrong)
- Transmits pressure forces, but no thermal loads
- Pressure force = Pressure x ”Thrust area”
 Hinge joint – Angular expansion joint
 Lateral expansion joint
Nozzle
 Simulate a vessel connection

by approximate the stiffnesses
using the entered vessel data
 Only the “soft” degrees of
freedom is set elastic – the
rest is rigid
 Cylindrical or spherical vessel
is considered
Workshop 6
 Nozzle
Sanity check of calculated results
” It is easy to be tempted to believe that calculated results are correct
after all the work you put into it”
 Don’t believe in the results because it comes from a computer. Ask yourself:
 Does this make sense?
 Can I give an explanation to why the results look like this?
Several simple checks and calculations can always be made:
 The sum of the mass of the complete piping system (including the fluid) must match the reaction forces in vertical
direction for all supports (dead load).
 The sum of reaction forces must be zero in all directions due to thermal load.
 Simple stress analysis using the formulas: σ = F/A, σ = Mb/W and σ = P x r/t may give a good indication on stress
levels in piping system.
 Has correct system of units being entered (MPa, bar (a), (e), (g), m, mm)?
Report generator
 Choose report template
 Create the report
 The report opens in Word
 The report is found in the

directory “R2DOC”
Eigenfrequency analysis
 Is used to be able to avoid

dangerous resonance vibrations
 Gives us an idea on how the

system will behave due to different
types of dynamic loads
Eigenfrequency analysis
 Add the load case Eigen values
 ROHR2 automatically adds internal

nodes to distribute the mass
 The results are normalized – no

real displacements!
Harmonic analysis
 Harmonic analysis:
 Investigate the damage due to a harmonic (sine wave) load
 Spectrum, modal analysis (earthquake analysis)

 Study ground acceleration effects on the piping system
 Transient analysis:
 Study the actions from arbitrary time varying loads on the
piping system
Buried piping
 Stress evaluation according to EN13941
 Define soil properties through Non linear soil restraint
 The data can be entered manually or chosen from standards,

e.g. EN13941
 A separate training course is available with respect to modelling

of buried piping and results evaluation
Buried piping
 Expansion cushions may be necessary
around bends, tees, etc. to allow certain
movements in these areas
 The thickness on the expansion cushions

should be about twice the amount of
displacement that appears without them
Buried piping
 Stiffness at tees
 Use an internal spring according to EN13941

for a more realistic stiffness -> reduces stress
Add-on modules
 ROHR2fesu
 ROHR2iso
 Included at
no cost
Workshop 7
 Close to reality workshop
Lycka till !

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ROHR2

Piping analysis part 1

 Introduction  Results evaluation

 Workshop 1, basic modelling

 Workshops are presented and important

 Pupils will do the workshops by themselves.

 Next lecture will start with comments and

 US civil war lasted between 1861 – 1865

 The industrialization increased a lot after the war

 10 000 boiler explosions in North Amerika 1865-1905

 Big accident in Massachusetts 1905 - 58 dead

 1907 – the first pressure vessel code in Massachusetts

 1911 – the first ASME code

 1949 – the first Swedish pressure vessel code (TKN)

 1955 – the first piping code in USA (B31.1)

 1967 – the first Swedish piping code (RN67)

 1972 – the first regulatory inspection requirements

 2002 – since June 1st, EN13480 is used within EU

 2017 – revision of EN13480

Common mistakes and pitfalls

This is valid for linear FEM based on the displacement

 Degrees of Freedom (DOF), translation and

Extra for piping elements in ROHR2:

 Material properties (usually constant within an element)

 Loads (transfers to nodes in the FEM-model) Beam theory is valid

 Calculation of stiffness properties

Q (N/m) Q x L/2 Q x L/2

Analysis process above is based on material data, geometry, loads,

1. Create stiffness matrices and load vectors [K], {F}

Displacements from given loads are calculated as:

2. Element analysis -> k

3. Assembling element matrices to global stiffness matrix-> K

4. Calculation of stresses and results evaluation against codes

Element stiffness matrix, Loop

Solving the equation system

effected by the FEM-errors (provided equally distributed loads)

 Local phenomena cannot not be considered since the beam

 FESU-module (add-on license) can study local phenomena

 In FEM (also in ROHR2) you either know the load or the

Current Output window Overall view

File new Save Print preview

File open Print Calculate

Selecting the current dimension

UNDO Transfer segment data Dimensions of jacket pipes

REDO Create Substructures Dimensions of structural sections

Draw Insert Substructures Line description

Select Pipe dimensions

Rigid support Rigid hanger Damper

Coordinate system 2 ZX- view

Node Nozzle Nonlinear soil restraint

Flange Angle valve Angular expansion joint

Point load Spectra combinations

Animation Reduce Output file spring design

Displacement scaling factor

1. Begin with drawing the main pipeline

2. Insert supports, components,

 Choose from built-in library

 Operating load cases with temperature/pressure combinations

 Anchor point movements