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<p>The global shift to non-conventional oil recovery has heightened the need for robust piping structures to address the fatigue life challenges. This research explores the combined effects of high-temperature fluids and solid particle flows on piping fatigue life through finite element analysis (FEA) with one-way fluid structure interaction (FSI). Various cases were developed and analyzed based on piping material, thickness, elbow angle, and fluid velocity. Optimized piping was design through multi-factor optimization approach incorporating high-temperature-resistant materials, ASME B36.10M thickness standards, and ASME 16.9 elbow angle modifications, maintaining oil processing efficiency. Fatigue life cycles were predicted using strain-life parameters and the Smith-Watson-Topper (SWT) mean stress theory, while stress-strain behavior was examined through hysteresis loops. Results revealed a 62.47 % improvement in fatigue life, enhancing the safety and reliability of piping structures. This study provides a framework for optimizing piping structures, advancing industry standards for safer, more efficient non-conventional oil plant operations.</p>

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Oil plant piping structure multi-factor optimization approach for enhancing fatigue life using one-way FSI analysis

  • 期刊论文

  • 发表日期：

    2025年7月1日

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  • Rabea Asif,
  • Heon Woo Lee,
  • Jong Wan Hu

摘要

The global shift to non-conventional oil recovery has heightened the need for robust piping structures to address the fatigue life challenges. This research explores the combined effects of high-temperature fluids and solid particle flows on piping fatigue life through finite element analysis (FEA) with one-way fluid structure interaction (FSI). Various cases were developed and analyzed based on piping material, thickness, elbow angle, and fluid velocity. Optimized piping was design through multi-factor optimization approach incorporating high-temperature-resistant materials, ASME B36.10M thickness standards, and ASME 16.9 elbow angle modifications, maintaining oil processing efficiency. Fatigue life cycles were predicted using strain-life parameters and the Smith-Watson-Topper (SWT) mean stress theory, while stress-strain behavior was examined through hysteresis loops. Results revealed a 62.47 % improvement in fatigue life, enhancing the safety and reliability of piping structures. This study provides a framework for optimizing piping structures, advancing industry standards for safer, more efficient non-conventional oil plant operations.