Design of hazardous mechanical structures, systems and components for extreme loads

310 Pages·2006·9.269 MB·English

by  Stevenson, John David, Coman, Ovidiu

DESIGN OF
HAZARDOUS
MECHANICAL
STRUCTURES,
SYSTEMS AND
COMPONENTS FOR
EXTREME LOADS
by
JOHN D. STEVENSON
and
OVIDIU COMAN
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©2006 by ASME,Three Park Avenue,New York,NY 10016,USA (www.asme.org)
All rights reserved. Printed in the United States of America. Except as permitted under the United
States Copyright Act of 1976,no part of this publication may be reproduced or distributed in any
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sion of the publisher.
INFORMATION CONTAINED IN THIS WORK HAS BEEN OBTAINED BY THE AMERICAN
SOCIETY OF MECHANICAL ENGINEERS FROM SOURCES BELIEVED TO BE RELI-
ABLE. HOWEVER,NEITHER ASME NOR ITS AUTHORS OR EDITORS GUARANTEE THE
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Library of Congress Cataloging-in-Publication Data
Stevenson,J. D. (John David),1933–
Design of hazardous mechanical structures,systems and components
for extreme loads / John D. Stevenson,Ovidiu Coman.
p. cm.
Includes bibliographical references and index.
ISBN 0-7918-0242-6
1. Structural stability—Standards. I. Coman,Ovidiu. II. Title.
TA656.S765 2006
624.1’72—dc22 2005031812
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A
CKNOWLEDGMENT
The authors wish to thank Dr. A.N. Bierbraer, St. Petersburg, Russia, author of Seismic Analysis of
Structures,Saint Petersburg,NAUKA 1998 and his earlier publications (in Russian) who was an inspira-
tion for this book and who made extremely valuable review comments. We also wish to thank Ms.
Margaret Pifer for her assistance in preparing figures and Mrs. Lori Bodziony for her preparation of the
book text.
iii
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F
ORWARD
This book is meant to identify and summarize the extreme loads to include loads resulting from exter-
nal natural phenomena and man-induced, as well as internal accident hazards phenomena applicable to
design of hazardous facility mechanical structures, systems and components. It includes first order defi-
nition of the loads and approximate analysis procedures used to design such mechanical structures, sys-
tems and components developed over the past 30 years for hazardous facilities to include nuclear,
petrochemical and biomedical facilities.
Chapter 1 identifies the extreme loads to be considered and industries to which the extreme loads apply.
It also identifies the design classifications and safety goals applied to mechanical Structures,Systems and
Components,SSC.
Chapter 2 discusses risk-based and risk-informed SSC Design Basis.
Chapter 3 identifies and describes generalized load phenomena.
Chapter 4 discusses design acceptance criteria as defined by the American society of mechanical
Engineers and related organization standards.
Chapter 5 addresses earthquake related design and analysis and Chapter 6 discusses in detail natural
hazard phenomena design loads other than seismic loads.
Chapter 7 addresses external blast load design and analysis and Chapter 8 high energy system (acci-
dent) SSC rupture loads.
Chapter 9 discusses vibration response of fluid distribution systems.
Chapter 10 covers extreme load design of buried tunnels,vaults and piping.
Chapter 11 discusses Quality Assurance and Control in Engineering,Construction and Procurement of
Safety Related Structures,Systems and Components in Hazardous Facilities.
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T C
ABLE OF ONTENTS
Acknowledgment...............................................................................................................................................iii
Forward..............................................................................................................................................................iv
1 Introduction....................................................................................................................................................1
1.1 Purpose......................................................................................................................................................1
1.2 Scope.........................................................................................................................................................1
1.2.1 Structures.....................................................................................................................................1
1.2.2 Distribution Systems...................................................................................................................1
1.2.3 Components.................................................................................................................................2
1.2.4 Standards.....................................................................................................................................2
1.3 Facilities Requiring Consideration of Extreme Loads..............................................................................4
1.3.1 Introduction.................................................................................................................................6
1.3.2 Nuclear Facilities.........................................................................................................................6
1.3.3 Petrochemical and Biomass Facilities.........................................................................................7
1.3.4 Bio-Hazard Facilities...................................................................................................................8
1.4 Description of Potential Design-Basis Hazards........................................................................................8
1.5 Loads Typically Considered in Design of Safety-Related Structures,Systems and
Components (SSC) in High-Hazard Facilities..........................................................................................8
1.5.1 Service Load................................................................................................................................8
Design Loads...........................................................................................................................8
1.5.2 Severe Loads...............................................................................................................................8
Human Occupancy..................................................................................................................8
Natural Hazards.......................................................................................................................8
Operating Transients Occasional and Upset Loads.................................................................9
1.5.3 Extreme Loads............................................................................................................................9
Natural Phenomena Hazards...................................................................................................9
Man-Induced External Hazards.............................................................................................11
Design-Basis Accidents.........................................................................................................13
Fire.........................................................................................................................................14
1.6 Categorization and Classification of Functional Safety-Related Mission Essential and Performance
Categorization of SSC and Procedures in Hazardous Facilities.............................................................14
1.6.1 Nuclear Industry........................................................................................................................14
Hazard Categorization...........................................................................................................14
Hazard Category 3 Facilities.................................................................................................14
Nuclear Hazard Category 2 Facilities...................................................................................15
Hazard Category 1 Facilities.................................................................................................16
Hazard Category 1s Facilities................................................................................................17
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vi Table of Contents
Functional and Performance Goals for Safety-Related SSC................................................17
Safety Goals...........................................................................................................................18
Performance Goals................................................................................................................19
Functional (Safety) Classifications of SSC...........................................................................19
Functional and Performance Classification of Safety-Related SSC.....................................19
Quality Classification............................................................................................................21
Design (Limit State) Classification.......................................................................................21
Recent Changes to Safety Classification of SSC Used in Nrc-Regulated Facilities............29
1.6.2 Petrochemical Industry..............................................................................................................30
Introduction...........................................................................................................................30
Natural Hazards.....................................................................................................................30
External Blast Load...............................................................................................................30
1.6.3 Bio-Medical Industry................................................................................................................30
1.7 References...............................................................................................................................................30
2 Risk-Based and Risk-Informed Design Bases...........................................................................................33
2.1 Introduction.............................................................................................................................................33
2.2 Probabilistic-Defined Safety Goals and Hazard Definition....................................................................33
2.3 Application of Probability Concepts for Evaluation of Service and Severe Loads................................35
2.3.1 Service or Normal Loads..........................................................................................................35
2.3.2 Anticipated Loads.....................................................................................................................36
Natural Hazards.....................................................................................................................36
Transient Operation Loads....................................................................................................37
2.4 Application of Probability Concepts for Evaluation of Extreme or Rare Natural Hazard Loads..........37
2.4.1 Design-Basis Earthquake Ground Motion................................................................................37
Step 1:Identification of Sources...........................................................................................37
Step 2:Recurrence Relationships,Magnitude,Distributions and Average Rates................37
Step 3:Ground Motion Estimation.......................................................................................38
Step 4:Construction of the Hazard Curve............................................................................39
Logic Trees and Uncertainty.................................................................................................40
The Gutenberg-Richter B-Line..............................................................................................41
Poisson Forecasting Model....................................................................................................41
2.4.2 Extreme and Rare Wind and Missile Velocities........................................................................42
Exceedence Probability and Return Period for Extreme Straight Winds.............................42
Exceedence Probability and Return Period for Rare Winds.................................................43
Wind-Borne Missile Velocities..............................................................................................47
2.4.3 Extreme and Rare Flood and Precipitation Parameters............................................................47
Extreme and Rare Floods and Precipitation..........................................................................47
Flood......................................................................................................................................47
Precipitation...........................................................................................................................48
2.5 Application of Probability Concepts for Evaluation of Man-Induced Accidental Extreme Loads........49
2.5.1 Introduction...............................................................................................................................49
2.5.2 Aircraft Hazard..........................................................................................................................50
2.5.3 Evaluation of Facility Upset and Accident Loads....................................................................53
Anticipated Transient Operation Upset Loads......................................................................53
High Energy System Rupture................................................................................................53
Heavy Load Drop..................................................................................................................54
2.6 Use of Code-Defined Importance Factors to Develop Probabilistic Hazard Curves..............................54
2.6.1 Basic Development....................................................................................................................54
2.6.2 Earthquake Hazard Curve.........................................................................................................54
2.6.3 Wind Hazard Curve...................................................................................................................54
2.6.4 Snow (Precipitation) Hazard Curve..........................................................................................55
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Table of Contents vii
2.7 Probabilistic Behavior and Design..........................................................................................................55
2.8 References...............................................................................................................................................55
3 Load Phenomena..........................................................................................................................................57
3.1 Introduction.............................................................................................................................................57
3.2 Static........................................................................................................................................................57
3.3 Dynamic...................................................................................................................................................58
3.3.1 Types of Dynamic Loads..........................................................................................................59
Cyclic Loads..........................................................................................................................59
Earthquake or other Building Filter-Cyclic Loads................................................................59
Fluter or Vortex-Shedding Loads..........................................................................................59
Impact Loads.........................................................................................................................59
Impulse Loads.......................................................................................................................59
3.3.2 Basic Equations of Motion and Time-Dependent Loading Functions.....................................60
Cyclic Loads..........................................................................................................................60
Impact Loads.........................................................................................................................61
Impulse Loads.......................................................................................................................62
3.4 Classification of Loads............................................................................................................................62
3.5 Loads Considered in Design of Hazardous Facilities.............................................................................63
3.6 References...............................................................................................................................................63
4 Acceptance Criteria.....................................................................................................................................65
4.1 Introduction.............................................................................................................................................65
4.2 ASME B&PVC Section III.....................................................................................................................67
4.2.1 Design by Analysis – Section NB-3200,NC-3200,WB-3200 and WC-3200.........................67
4.2.2 Design by Rule NX and WX-3100 and NX and WX-3300.....................................................72
4.2.3 Piping Design – Article NX-3600.............................................................................................74
Class 1 – Subsection NB-3600..............................................................................................74
Class 2 and 3 – Subsections NC-3600 and ND-3600...........................................................76
4.2.4 Support Design..........................................................................................................................77
Introduction...........................................................................................................................77
Acceptance Criteria...............................................................................................................77
4.3 ASME B&PVC Section VIII...................................................................................................................82
4.3.1 ASME B&PVC Section VIII Division 1 Rules for Construction of Pressure Vessels.............86
Design of Shells for Internal Pressure...................................................................................86
4.3.2 ASME B&PVC Section VIII Division 2 Alternate Rules for Construction of
Pressure Vessels.........................................................................................................................86
4.4 ASME B31.3 Process Piping...................................................................................................................87
4.4.1 Introduction...............................................................................................................................87
4.4.2 Design Criteria..........................................................................................................................87
Straight Pipe Under Internal Pressure...................................................................................87
4.5 ASME B31.1 Power Piping.....................................................................................................................88
4.6 References...............................................................................................................................................92
5 Earthquake Design and Analysis................................................................................................................95
5.1 Introduction.............................................................................................................................................95
5.1.1 Purpose of Seismic Design.......................................................................................................95
5.1.2 Seismic Design Procedures.......................................................................................................95
5.2 Earthquake Physical Phenomena.............................................................................................................96
5.2.1 Faults.........................................................................................................................................96
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viii Table of Contents
5.2.2 Focus and Epicenter Ground Motion........................................................................................96
5.2.3 Attenuation of Motion with Distance from the Epicenter........................................................97
5.2.4 Intensity.....................................................................................................................................97
5.2.5 Magnitude..................................................................................................................................98
5.2.6 Seismic Hazard Curve...............................................................................................................99
5.3 Seismic Load Definition........................................................................................................................100
5.3.1 Static........................................................................................................................................101
Seismic Forces.....................................................................................................................101
Seismic Relative Static Displacements...............................................................................105
Component and Systems Supports and Anchorage.............................................................105
5.3.2 Equivalent Static......................................................................................................................106
5.3.3 Dynamic-Response Spectrum Modal Analysis.......................................................................109
5.3.4 Dynamic Time History............................................................................................................113
Equations of Motion............................................................................................................113
Modal Analysis....................................................................................................................114
5.4 Response Spectra...................................................................................................................................116
5.4.1 Ground.....................................................................................................................................116
Nuclear.................................................................................................................................116
Petrochemical and Biomedical............................................................................................125
5.4.2 Floor or in-Structure................................................................................................................125
5.4.3 Equipment...............................................................................................................................127
5.5 Determination of Seismic Loads on Structural Systems.......................................................................128
5.5.1 Introduction.............................................................................................................................128
5.5.2 Cantilever Systems..................................................................................................................128
Illustrative Problem.............................................................................................................128
ASCE 7-05 Computations of Seismic Forces.....................................................................129
Equivalent Static Analysis...................................................................................................131
Response Spectrum Modal Analysis...................................................................................134
Dynamic Time History Modal Analysis..............................................................................138
Dynamic Time History Direct Integration Analysis............................................................138
Summary of Air Tank Analysis Results..............................................................................144
5.5.3 Piping Continuous Over Multiple Support Systems...............................................................144
Static....................................................................................................................................145
ASCE-7 Method of Design.................................................................................................147
Equivalent Static..................................................................................................................147
Dynamic...............................................................................................................................147
Modal Response Spectrum S Analysis................................................................................147
Time History Modal Analysis.............................................................................................149
Time History Direct Integration..........................................................................................149
Summary..............................................................................................................................153
5.6 Coupled Versus Uncoupled Dynamic Analysis of Mechanical (Secondary) Systems..........................153
5.7 Development and use of Spacing Tables and Charts for Seismic Design of Piping and other
Distribution Systems..............................................................................................................................154
5.7.1 Introduction.............................................................................................................................154
5.7.2 Development of Lateral Support Spacing and Inertia Acceleration.......................................154
Span Lengths.......................................................................................................................155
Allowable Stresses...............................................................................................................156
Seismic Loading..................................................................................................................157
5.7.3 Design Charts for Various Pipe Configurations......................................................................157
Derivation of the Charts......................................................................................................158
Use of Charts.......................................................................................................................158
5.8 References.............................................................................................................................................159
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Table of Contents ix
6 Natural Hazard Design and Analysis other than Earthquake..............................................................161
6.1 Wind.......................................................................................................................................................161
6.2 Physical Phenomena..............................................................................................................................162
6.2.1 Straight Winds.........................................................................................................................162
6.2.2 Hurricanes,Cyclones and Typhoons.......................................................................................162
6.2.3 Tornadoes................................................................................................................................163
Applied to Nuclear Power Plants........................................................................................163
Applied to other DOE Nuclear Facilities............................................................................164
Petrochemical and Biomedical Hazardous Facilities..........................................................164
Historical Development of the Tornado Design Requirement............................................164
Description of the Tornado Wind Phenomenon..................................................................164
Tornado Classification.........................................................................................................166
Tornado Wind Field Simplified Analytical Models.............................................................167
6.3 Load Definition......................................................................................................................................168
6.3.1 Wind Pressure..........................................................................................................................168
6.3.2 Differential Pressure................................................................................................................169
6.3.3 Missiles....................................................................................................................................169
Impact..................................................................................................................................169
Penetration...........................................................................................................................170
6.4 Wind Design and Construction of Mechanical Components and Supports..........................................170
6.4.1 Mechanical Structures.............................................................................................................170
6.4.2 Distribution Systems...............................................................................................................170
6.4.3 Ventilators and Filters.............................................................................................................170
6.5 In-Line Wind and Differential Pressure Loading..................................................................................170
6.5.1 Openings..................................................................................................................................171
6.5.2 Dynamic Load Considerations................................................................................................171
Vortex Shedding Design Methodology...............................................................................172
General Theory....................................................................................................................172
Practical Application...........................................................................................................173
Equivalent Static Loads.......................................................................................................173
Variable Diameter Stacks or Towers...................................................................................173
6.6 Missile Loads.........................................................................................................................................175
6.6.1 Penetrating...............................................................................................................................175
6.6.2 Inelastic Structural Response..................................................................................................175
6.7 Flood and Precipitation Load................................................................................................................175
6.7.1 Introduction.............................................................................................................................175
6.7.2 Loads During Flooding...........................................................................................................176
Hydrostatic Loads................................................................................................................176
Hydrodynamic Loads..........................................................................................................176
Wave Loads.........................................................................................................................176
Breaking Wave Loads on Vertical Walls or Plates..............................................................177
6.8 Volcano Effects......................................................................................................................................177
6.9 Lightening Protection............................................................................................................................177
6.9.1 Introduction.............................................................................................................................177
6.9.2 Protection System Design.......................................................................................................178
Types of Lightning protection Systems...............................................................................178
Striking Distance Requirement...........................................................................................178
6.9.3 Facility Protection...................................................................................................................178
Side Flash............................................................................................................................178
Incoming Utility Requirements...........................................................................................178
6.10 References.............................................................................................................................................179
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x Table of Contents
7 Blast Design and Analysis.........................................................................................................................181
7.1 Introduction...........................................................................................................................................181
7.2 Explosive Quantity and Distance and Resultant Pressures and Durations...........................................183
7.3 Equivalent Static Loads (ESL)..............................................................................................................185
7.3.1 Calculation of ESL..................................................................................................................188
7.4 Damage and Failure of Buildings,Primary Load Path,Architectural Features,
Contents and Occupants........................................................................................................................188
7.5 Example Problems.................................................................................................................................189
7.5.1 Example 1................................................................................................................................189
7.5.2 Example 2................................................................................................................................189
7.5.3 Example 3................................................................................................................................189
7.6 Design Action of Shield Structures.......................................................................................................190
7.7 References.............................................................................................................................................190
8 High-Energy Systems Extreme Load Design and Analysis...................................................................191
8.1 Pipe Rupture and Leakage Effects........................................................................................................191
8.1.1 Introduction.............................................................................................................................191
8.1.2 Leak Before Break..................................................................................................................191
8.1.3 Pipe Rupture Effects...............................................................................................................192
Jet Reaction.........................................................................................................................192
Jet Impingement..................................................................................................................193
Jet Load Design Procedures................................................................................................193
Typical Fluid Forcing Functions.........................................................................................195
Pipe Whip............................................................................................................................196
Effects of Pipe Whip...........................................................................................................196
Membrane Stability of Plastic Hinged Pipes......................................................................198
8.1.4 Current Analytical Procedures for Generation of Pipe Rupture Loads and Jet Forces..........198
8.1.5 Jet Impingement Loads...........................................................................................................198
8.1.6 Pipe Whip Restraint Design....................................................................................................199
Steel Frames........................................................................................................................199
Steel Cables.........................................................................................................................199
Steel Bands..........................................................................................................................200
8.1.7 Simple Sample Problem Illustrating the Effect of Ductility in Restraint Design..................200
8.2 Missiles..................................................................................................................................................202
8.2.1 Introduction.............................................................................................................................202
8.2.2 Missile Source Definition........................................................................................................202
Pressurized Equipment Missiles..........................................................................................202
Tornado and Extreme Wind Generated Missiles.................................................................202
Aircraft Accident Crash Missiles........................................................................................202
Rotating Machinery Missiles...............................................................................................203
Design-Basis Missiles.........................................................................................................203
8.2.3 Determination of Missile Design Velocity..............................................................................203
Missiles Resulting from Plant Operation............................................................................203
Piston-Type Missile.............................................................................................................203
Jet-Propelled Missiles..........................................................................................................204
Self-Propelled Missiles........................................................................................................205
Missiles from Rotating Machinery......................................................................................205
Missiles Originating from Stored Strain Energy.................................................................205
Missiles from Ruptured Vessels..........................................................................................205
8.2.4 Missile Effects.........................................................................................................................206
Missile Penetration..............................................................................................................206
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