Pipe Stress Analysis

In piping engineering, pipe stress analysis is one of the most critical processes. It ensures piping systems can withstand thermal expansion, pressure loads, mechanical vibrations, and external forces without failure. As a result, projects benefit from improved safety, reliability, and regulatory compliance.

At Mechansys, our engineers bring over 25 years of experience to every project. Not only have we delivered stress-free piping design, but we have also demonstrated the ability to resolve complex challenges as they arise. By using advanced software, adhering to international codes, and optimising pipe supports, our team has successfully mitigated risks and extended the lifespan of piping systems.

Industries We Serve

Our pipe stress analysis services have supported industries such as oil and gas, petrochemical, and power generation. Across these sectors, we address issues like:

• Excessive nozzle loads on equipment

• Pipe buckling caused by compressive stress

• Fatigue failure due to vibration

• Water hammer-induced stress

• High thermal stress in hot pipelines

By identifying these challenges early, we create a robust and well-planned stress analysis strategy.

Pipe Stress Analysis Methodology

We follow a systematic, step-by-step approach to deliver accurate results:

Step 1: Collecting Input Data

We gather essential details such as pipe material, site operating conditions, and planned dimensions.

Step 2: 3D Modelling & Finite Element Analysis (FEA)

Using software like AutoCAD or PDMS, we create a 3D model of the piping system. Then, we run FEA to calculate stress distribution across different sections.

Step 3: Load Case & Boundary Condition Analysis

We assess:

• Thermal cases (hot/cold conditions)

• Pressure cases (design vs. operating pressure)

• Sustained cases (weight + pressure)

• Occasional cases (seismic, wind, water hammer)

Step 4: Stress Calculations

• Primary stresses → From pressure and weight (checked against allowable limits)

• Secondary stresses → From thermal expansion (evaluated for fatigue resistance)

• Displacement stresses → Including nozzle loads on equipment

Step 5: Code Compliance Checks

We verify compliance with global standards like ASME B31.3, API 570, and EN 13480.

Step 6: Support Optimisation

We adjust support locations to reduce stresses and, when necessary, recommend springs, snubbers, or dampers to enhance flexibility.

Step 7: Reporting & Recommendations

Finally, we provide a stress summary report with colour-coded stress plots and propose modifications wherever stress levels exceed allowable limits.

Why Choose Mechansys?

A well-executed pipe stress analysis prevents leaks, pipe ruptures, and structural damage. More importantly, it ensures your piping system remains compliant and reliable for years to come.

With decades of expertise and cutting-edge tools, Mechansys is your trusted partner for achieving safe, efficient, and sustainable piping systems.

Let us help secure your piping systems for today and tomorrow. Contact us for a free assessment or demo!

You can also look at our case studies on piping design and pipe stress analysis here.