Comprehensive Stress Analysis and Optimal Support Selection for Pipeline System

Abstract Pipeline systems play a crucial role in transporting fluids and gases across industrial facilities. These infrastructures subjected to multifaceted and fluctuating loading conditions, including internal pressure, gravitational forces, thermal expansion, and external vibrations. In the situation where these mechanical stresses are not adequately controlled or mitigated, it can lead to structural fatigue, material deformation, endangering personnel safety and causing economic losses. This study focuses on analysing the stress behaviour of pipeline systems before and after the implementation of optimized support structures, utilizing Bentley AutoPIPE software and data collected from the Naphthalene Process Plant project. By simulating real-world pipeline configurations, this research identifies stress hotspots including elbows, tees, and long unsupported spans. This study also evaluates the effectiveness of support systems, including hanger springs, guides, line stops, and V-stops. The results from simulation and manual calculations demonstrate that proper support installation can reduce stress levels by over 80% and displacement from approximately 18 mm to less than 2.5 mm. These findings highlight the crucial role of support optimization in improving pipeline resilience, maintaining alignment, and ensuring compliance with ASME B31.3 standards. This study provides valuable insights for industries aiming to improve safety, operational efficiency, and extend service life of pipeline system.