CAESAR II Technical Reference Manual Copyright 1993-2004 COADE, Inc. All Rights Reserved. Printed on 18 November, 2003

1 Contents Chapter 1: Introduction 1 Overview ....................................................................... ...............................................................................2 Program Support / User Assistance ............................................. .................................................................3 COADE Technic al Support ..................................................................... .....................................................4 Chapter 2: Configuration and Environment 1 Generation of the CAESAR II Configuration File.................................. ......................................................2 Computation Control .... ................................................................................ ................................................3 Use Pressure Stiffening ...... ................................................................................ ...............................3 Missing Mass ZPA .............................. ................................................................................ ..............3 Bend Axial Shape ............................................... ...............................................................................3 Rod Tolerance (degrees)........................................................ ............................................................4 Rod Increment (deg rees) .......................................................................... .........................................4 Alpha Tolerance ..................... ................................................................................ ...........................4 Ambient Temperature................................ ................................................................................ ........4 Friction Stiffness ................................................... ............................................................................4 Fr iction Normal Force Variation .................................................. .....................................................5 Friction Angle Variation. ................................................................................ ...................................5 Friction Slide Multiplier ................. ................................................................................ ...................5 Coefficient of Friction (Mu) .............................. ................................................................................ 5 WRC-107 Version .............................................................. ...............................................................5 WRC-107 Interpo lation Method................................................................... .....................................5 Incore Numerical Check .................. ................................................................................ ..................5 Decomposition Singularity Tolerance ........................ .......................................................................6 Minimum Wall Mill Tolerance (%)........................................................ ...........................................6 Bourdon Pressure................... ................................................................................ ............................7 Ignore Spring Hanger Stiffness ................... ................................................................................ ......7 Include Spring Stiffness in Hanger OPE Travel Cases..................... .................................................7 Hanger Default Restraint Stif fness .......................................................................... ..........................8 Default Translational Restraint Stiffness........... ................................................................................ 8 Default Rotational Restraint Stiffness ....................................... ........................................................8 SIFs and Stresses ....

................................................................................ ......................................................9 Default Code............ ................................................................................ ..........................................9 Occasional Load Factor ............. ................................................................................ ......................10 Yield Stress Criterion ................................ ................................................................................ ......11 B31.3 Sustained Case SIF Factor ....................................... .............................................................12 B31.3 Welding an d Contour Insert Tees Meet B16.9................................................ ......................13 Allow User's SIF at Bend .............................. ................................................................................ ..13 Use WRC329................................................................. ..................................................................13 Use Schneid er ............................................................................. .....................................................13 All Cases Corroded...... ................................................................................ ....................................13 Liberal Expansion Stress Allowable....... ................................................................................ .........14 WRC 329 ............................................................ .............................................................................14 Base Hoop Stress On ( ID/OD/Mean/Lams )........................................... ......................................14 Use PD/4t ............................. ................................................................................ ...........................14

2 Contents Add F/A in Stresses ................................................... ......................................................................14 Add Tor sion in SL Stress............................................................... ..................................................15 Stress Stiffening Due to Pr essure ......................................................................... ...........................15 Reduced Intersection ............................. ................................................................................ ..........16 Class 1 Branch Flexibility ........................................ .......................................................................17 B31.1 Reduced Z Fix................................................................... ....................................................17 Schneider ............... ................................................................................ ..........................................17 No RFT/WLT in Reduced Fitting SIFs ................................................................................ ...........17 Apply B31.8 Note 2................................................ .........................................................................17 Pres sure Variation in Expansion Cases .............................................. .............................................17 Geometry Directives ............ ................................................................................ .......................................18 Connect Geometry Through Cnodes ...... ................................................................................ .........18 Auto Node Number Increment ......................................... ...............................................................18 Z-Axis Vertica l .............................................................................. ..................................................19 Minimum Allowed Bend Angle ................................................................................ ......................19 Maximum Allowed Bend Angle............................. .........................................................................19 Bend Length Attachment Percent ..................................................... ...............................................19 Minimum Angle to Adjacent Bend ................................................................................ ..................19 Loop Closure Tolerance .................................... ..............................................................................19 Horizontal Thermal Bowing Tolerance ........................................... ................................................20 Plot Colors ................. ................................................................................ .................................................21 OPENGL Switch .............. ................................................................................ ...............................21 Pipes ........................................ ................................................................................ ........................21 Nodes................................................ ................................................................................ ...............21 Rigids/Bends.................................................. ................................................................................ ..21 Hangers/Nozzles............................................................ ..................................................................22 Structure . ................................................................................ .........................................................22 Background.......... ................................................................................ ............................................22 Axes............................. ................................................................................ ....................................22 Labels .................................. ................................................................................ ............................22 Highlights ...................................... ................................................................................ ..................22 Displaced Shape ........................................... ................................................................................ ...22 Stress Level 1 ...........................................................

.......................................................................22 Stress Level 2 ....................................................................... ...........................................................22 Stress Level 3 ... ................................................................................ ...............................................22 Stress Level 4 ............... ................................................................................ ...................................22 Stress Level 5 ........................... ................................................................................ .......................22 Stress < Level 1 ..................................... ................................................................................ ..........23 Stress > Level 1 .................................................. .............................................................................23 Stress > Level 2 ............................................................... ................................................................23 Stress > Leve l 3 ............................................................................ ...................................................23 Stress > Level 4 ......... ................................................................................ ......................................23 Stress > Level 5 ...................... ................................................................................ .........................23 FRP Pipe Properties ................................ ................................................................................ ....................24 Use FRP SIF ............................................. ................................................................................ .......24 Use FRP Flexibilities................................................. ......................................................................24 FRP Pro perty Data File................................................................. ...................................................25 BS 7159 Pressure Stiffenin g............................................................................... .............................25 FRP Laminate Type............................... ................................................................................ ..........25 Exclude f2 from UKOOA Bending Stress............................... ........................................................26 FRP Pipe Density .... ................................................................................ ........................................26 FRP Alpha (e-06) .................... ................................................................................ ........................26 FRP Modulus of Elasticity ........................... ................................................................................ ...26 Ratio Shear Mod:Emod ..................................................... ..............................................................26 Axial Strain:Ho op Stress (Ea/Eh*Vh/a) ......................................................... .................................26

Contents 3 Database Definitions............................................................ .......................................................................27 Struct ural Database................................................................... .......................................................27 Piping Size Specificat ion (ANSI/JIS/DIN/BS)........................................................... .....................27 Valves and Flanges...................................... ................................................................................ ....27 Expansion Joints ........................................................ ......................................................................28 Units F ile Name........................................................................ .......................................................28 Load Case Template ... ................................................................................ .....................................28 System Directory Name................... ................................................................................ ................28 Default Spring Hanger Table.................................. .........................................................................28 Enab le Data Export to ODBC-Compliant Databases ..................................... .................................28 Append Reruns to Existing Data ............. ................................................................................ ........29 ODBC Compliant Database Name ........................................ ..........................................................29 Miscellaneous ..... ................................................................................ ........................................................30 Output Table of Conte nts ............................................................................ ....................................30 Output Reports by Load Case.............. ................................................................................ ............30 Displacement Reports Sorted by Nodes ............................ ..............................................................30 Time History An imation......................................................................... .........................................31 Dynamic Example Input Text.......... ................................................................................ ................31 Memory Allocated............................................. ..............................................................................31 User ID ....................................................................... .....................................................................31 Disable "File Open" Graphic Thumbnail................................................... ......................................31 Disable Undo/Redo Ability ............. ................................................................................ ................32 Enable Autosave ............................................. ................................................................................ .32 Autosave Time Interval ..................................................... ..............................................................32 Prompted Autosa ve ............................................................................. ............................................32 Set/Change Password.............. ................................................................................ ....................................33 Access Protected Data ................... ................................................................................ ..................33 New Password .............................................. ................................................................................ ...33 Change Password........................................................... ..................................................................33 Remove Pass word ........................................................................... ................................................33 Units File Operations ....... ................................................................................ ...........................................34 Make Units File .................. ................................................................................

.............................34 Review Existing Units File...................... ................................................................................ ........34 Create a New Units File.............................................. .....................................................................35 Existing File to Start From ............................................................ ..................................................36 New Units File Name ....... ................................................................................ ...............................36 View/Edit File ............................... ................................................................................ ..................36 Convert Input to New Units................................. ................................................................................ .......37 Name of the Input File to Convert..................................... ..............................................................37 Name of the Uni ts File to Use ................................................................. ........................................37 Name of the Converted File........... ................................................................................ ..................37 Material Database ......................................... ................................................................................ ..............38 Material - Add ................................................ ................................................................................ .38 Material - Delete........................................................... ...................................................................38 Material Edit........................................................................... .......................................................39 Chapter 3: Piping Screen Reference 1 Piping Spreadsheet Data ........................................................ .......................................................................2 Help Sc reens and Units................................................................. .....................................................2 Auxiliary Fields - Compon ent Information ................................................................ ................................14 Bends ....................................... ................................................................................ ........................14 Rigid Elements ...................................... ................................................................................ ..........18 Expansion Joints .................................................. ............................................................................19

4 Contents Reducers .............................................................. ............................................................................20 S IFs & Tees ..................................................................... ................................................................22 Auxiliary Fie lds - Boundary Conditions....................................................... ..............................................31 Restraints .................... ................................................................................ .....................................31 Hangers................................. ................................................................................ ...........................36 Nozzles .......................................... ................................................................................ .............................48 Nozzle Flexibility - WRC 297.................... ................................................................................ .....48 Displacements........................................................... .......................................................................57 Auxili ary Fields - Imposed Loads...................................................... .........................................................58 Forces and Moments.. ................................................................................ ......................................58 Uniform Loads.......................... ................................................................................ .......................58 Wind Loads ........................................... ................................................................................ ..........59 Wave Loads ........................................................ .............................................................................60 Auxiliary Fields - Piping Code Data............................................. ..............................................................62 Allowable Stres ses............................................................................. ..............................................62 Available Commands............. ................................................................................ .....................................79 Break Command .......................... ................................................................................ ....................79 Valve/Flange Database ................................... ................................................................................ .81 Find Distance............................................................... ....................................................................84 Find Elem ent ............................................................................ .......................................................84 Global Coordinates ... ................................................................................ .......................................85 Insert Element........................ ................................................................................ ..........................85 Node Increment .................................... ................................................................................ ...........85 Show Informational Messages....................................... ..................................................................85 Tee SIF Scr atchpad......................................................................... .................................................85 Bend SIF Scratchpad ........ ................................................................................ ...............................91 Expansion Joint Modeler ...................... ................................................................................ ...........95 Expansion Joint Modeler Notes..................................... ..................................................................98 Expansion J oint Design Notes .............................................................. ...........................................99 Torsional Spring Rates ........... ................................................................................ .........................99 Bellows Application Notes .......................... ................................................................................ ..100 Available Expansion Joint End-Types....................................... ....................................................100 Pressure Rating ........

................................................................................ ......................................101 Expansion Joint Styles................ ................................................................................ ...................101 Materials ............................................... ................................................................................ .........102 Title Page......................................................... ..............................................................................10 3 Hanger Data................................................................... ................................................................103 Special Exec ution Parameters................................................................ ........................................109 Combining Independent Piping Systems ................................................................................ .......119 List/ Edit Facility ................................................. ..........................................................................121 Bl ock Operations ................................................................. ..........................................................123 Printing an Input Listing......................................................................... .......................................126 Input Plotting ...................... ................................................................................ ...........................127 Model Rotation, Panning, and Zooming............. ...........................................................................127 V iews............................................................................ .................................................................129 Volume Plot ting............................................................................ .................................................129 Displaying Element Informat ion ............................................................................ .......................129

Contents 5 Piping Input Graphics .......................................................... .....................................................................131 Static Output Graphics................................................................. .............................................................134 Chapter 4: Structural Steel Modeler 1 Overview ....................................................................... ...............................................................................2 The Structural Steel Property Editor........................................... ..................................................................3 New File ... ................................................................................ .........................................................3 Units File .......... ................................................................................ .................................................4 Vertical Axis................ ................................................................................ ......................................5 Material Properties .................... ................................................................................ ........................6 Cross Section (Section ID) ........................... ................................................................................ .....7 Model Definition Method ................................................. ...............................................................10 General Proper ties............................................................................ ...........................................................12 Add .............. ................................................................................ ....................................................12 Insert................... ................................................................................ .............................................12 Replace ........................ ................................................................................ ....................................12 Delete................................... ................................................................................ ............................12 UNITS Specification - UNIT....................... ................................................................................ ...............13 Axis Orientation Vertical..................................... ................................................................................ .......14 Material Identification - MATID ...................................... ..........................................................................15 MAT ID.............................................................................. ..............................................................15 YM............. ................................................................................ ......................................................15 POIS .................. ................................................................................ ..............................................16 G ............................. ................................................................................ .........................................16 YS.................................. ................................................................................ ..................................16 DENS....................................... ................................................................................ ........................16 ALPHA................................................ ................................................................................ ............16 Section Identification - SECID .................................. ................................................................................ .17 Section ID.................................................................. ......................................................................17 SECID .

................................................................................ ............................................................17 Name ............ ................................................................................ ...................................................18 Setting Defaults - DEFAULT ............................................................................... ......................................19 Setting Nodes in Space - NODE, NFILL, N GEN............................................................................. ..........20 NODE .............................................................. ................................................................................ 20 NFILL........................................................................ ......................................................................21 NGEN... ................................................................................ ...........................................................22 Building Elements - ELEM, EFILL, EGEN, EDIM....................................................... ............................24 ELEM ............................................ ................................................................................ ..................24 EFILL ..................................................... ................................................................................ .........25 EGEN ............................................................... ...............................................................................2 7 EDIM.......................................................................... .....................................................................29 Resettin g Element Strong Axis - ANGLE, ORIENT........................................... .......................................32 ANGLE ................................ ................................................................................ ...........................32 ORIENT ........................................... ................................................................................ ...............33 End Connection Information.................................... ................................................................................ ...35 Free End Connections - FREE............................................... ..........................................................35 Standard Structural Element Connections - BEAMS, BRACES, COLUMNS ...............................38 BRACES ......................................................................... ................................................................40 COLUMNS ..... ................................................................................ ................................................42 Defining Global Restraints FIX ............................................................................ ........................44 Loads ............................................... ................................................................................ ...........................46 Point Loads - LOAD................................ ................................................................................ ........46 Uniform Loads - UNIF ................................................ ....................................................................48

6 Contents Gravity Loads - GLOADS................................................. ..............................................................50 Wind Loads - WI ND ............................................................................. ..........................................51 Utilities ......................... ................................................................................ ..............................................53 LIST........................... ................................................................................ ......................................53 Structural Databases .................. ................................................................................ .................................54 AISC 1977 Database ......................... ................................................................................ ..............55 AISC 1989 Database ............................................ ...........................................................................61 Ge rman 1991 Database.............................................................. ......................................................68 Australian 1990 Databas e............................................................................... .................................71 South African 1992 Database ................ ................................................................................ ..........73 Korean 1990 Database............................................... ......................................................................74 UK 1993 Database....................................................................... ....................................................75 Chapter 5: Controlling the Dynamic Solution 1 Dynamic Analysis Input ......................................................... ......................................................................2 Dynamic Analysis Overview .............................................................. ..........................................................3 Random ............. ................................................................................ ................................................3 Harmonic ..................... ................................................................................ ......................................3 Impulse ................................ ................................................................................ ..............................6 Harmonic Analysis .............................. ................................................................................ .........................8 Excitation Frequencies .............................. ................................................................................ ........8 Harmonic Forces and Displacements .................................... ..........................................................11 Harmonic Displaceme nts............................................................................. ....................................13 Response Spectra / Time History Load Prof iles ........................................................................... ..............16 Response Spectrum / Time History Profile Data Point Input ..... .....................................................21 Force Response Spectrum Definitions..................................................................... ........................22 Building Spectrum / Time History Load Cases ......... ................................................................................ .24 Spectrum /Time History Profile.............................................. .........................................................24 Factor.............. ................................................................................ .................................................24 Direction .................. ................................................................................ ........................................25 Combining Static and Dynamic Results ................................................................................ ..........32 Spectrum Time History..............................................

................................................................................ .38 Force....................................................................... .........................................................................38 Dire ction .......................................................................... ................................................................38 Node ........ ................................................................................ ........................................................38 Force Set #.......... ................................................................................ .............................................38 Lumped Masses .................. ................................................................................ ........................................44 Mass................................. ................................................................................ ................................44 Direction ................................... ................................................................................ .......................44 Start Node............................................ ................................................................................ ............44 Stop Node ....................................................... ................................................................................ .45 Increment................................................................... ......................................................................45 Snubber s .............................................................................. ............................................................46 Dynamic Control P arameters....................................................................... ...............................................48 Analysis Type (Harmonic/Spectr um/Modes/Time-History) ......................................................... ..49 Static Load Case for Nonlinear Restraint Status............................ ..................................................62 Stiffness Factor for Fricti on (0.0 - Not Used)............................................................. .....................63 Max. No. of Eigenvalues Calculated (0-Not used) ........ ..................................................................64 Frequency C utoff (HZ) ..................................................................... ...............................................67 Closely Spaced Mode Criteria/T ime History Time Step (ms) ..................................................... ....68 Load Duration (Time History or DSRSS Method) (Sec.)...................... ..........................................69 Damping (Time History or DSRSS) (Ra tio of Critical) ............................................................... ...69 ZPA (Reg. Guide 1.60/UBC- G's)/# Time History Output Cases ............... ....................................71

Contents 7 Re-use Last Eigensolution ...................................................... .........................................................73 Spatial or Modal Com bination First ................................................................. ...............................73 Spatial Combination Method (SRSS/ABS) ........ .............................................................................74 Modal Combination Method (GROUP/10%/DSRSS/ABS/SRSS)............................. .....................74 Include Pseudostatic (Anchor Movement) Components (Y/N) .......................................................77 Include Missing Mass C omponents (Y/N) ................................................................ ......................78 Pseudostatic (Anchor Movement) Comb. Method (SRSS/ABS). ....................................................78 Missing Mass Combination Method (SRSS/ABS) .............................................................. ............78 Directional Combination Method (SRSS/ABS) ....................... .......................................................79 Sturm Sequence Check o n Computed Eigenvalues (Y/N).................................................... ...........79 Advanced Parameters .............................................. ................................................................................ ...81 Estimated Number of Significant Figures in Eigenvalues ................... ............................................81 Jacobi Sweep Tolerance .......... ................................................................................ ........................82 Decomposition Singularity Tolerance ................. ............................................................................82 S ubspace Size (0-Not Used) ...................................................... ......................................................82 No. to Converge Before Shift Allowed (0 - Not Used) ................................................... ................83 No. of Iterations Per Shift (0 - Pgm computed) .............. .................................................................83 Percent of I terations Per Shift Before Orthogonalization ................................... .............................84 Force Orthogonalization After Convergence (Y/N) ........................................................................84 Use O ut-Of-Core Eigensolver (Y/N).................................................... ...........................................84 Frequency Array Spaces ........... ................................................................................ .......................84 Pulsation Loads....................................... ................................................................................ ....................85 Relief Valve Thrust Load Analysis........................ ................................................................................ .....88 Relief Load Synthesis for Gases Greater Than 15 psig ................... ................................................88 Relief Load Synthesis for Liq uids ........................................................................... ........................94 Output From the Liquid Relief Load Synthesizer....... .....................................................................96 Chapter 6: Technical Discussions 1 Rigid Element Application ...................................................... .....................................................................2 Rigid Mat erial Weight ................................................................... ....................................................2 Rigid Fluid Weight ....... ................................................................................ .....................................2 Rigid Insulation Weight.................. ................................................................................ ...................2 Cold Spring................................................ ................................................................................

...................4 Expansion Joints .......................................... ................................................................................ .................7 Hanger Sizing Algorithm...................................... ................................................................................ ......10 Spring Design Requirements ............................................ ...............................................................10 Restrained Wei ght Case........................................................................ ...........................................10 Operating Case ................... ................................................................................ .............................11 Installed Load Case ............................ ................................................................................ .............11 Setting Up the Spring Load Cases ............................... ....................................................................12 Constant Effort Support.................................................................. .................................................12 Including the Spring Hanger Stiffness in the Design Algorithm .............................................. .......13 Other Notes on Hanger Sizing.......................................... ...............................................................13 Class 1 Branch Flexibilities ................................................................. .......................................................14 Modeling Friction Effe cts ............................................................................ ...............................................17 Nonlinear Code Compliance..... ................................................................................ ..................................19 Sustained Stresses and Nonlinear Restraints ............................................................................... ...............20 Notes on Occasional Load Cases................................ .....................................................................23 Static S eismic Loads.................................................................... ...............................................................24 Wind Loads.... ................................................................................ .............................................................27 Elevation....... ................................................................................ ...................................................29 Hydrodynamic (Wave and Cur rent) Loading .................................................................. ...........................30 Ocean Wave Particulars............................ ................................................................................ .......31

8 Contents Applicable Wave Theory Determination .................................. .......................................................32 Pseudo-Static Hydrodyn amic Loading ................................................................... .........................32 AIRY Wave Theory Implementation .................... ..........................................................................33 STO KES Wave Theory Implementation ................................................. ........................................34 Stream Function Wave Theory Implement ation........................................................................... ...34 Ocean Currents ........................................................... .....................................................................34 Technica l Notes on CAESAR II Hydrodynamic Loading....................................... ........................35 Input: Specifying Hydrodynamic Parameters in CAESAR I I .........................................................39 Current Data ..... ................................................................................ ...............................................39 Wave Data .................... ................................................................................ ...................................41 Seawater Data............................. ................................................................................ .....................42 Piping Element Data..................................... ................................................................................ ...42 References ............................................................... ........................................................................42 Evalu ating Vessel Stresses........................................................... ...............................................................44 ASME Section V III Division 2 - Elastic Analysis of Nozzle .................................... ......................44 Procedure to Perform Elastic Analyses of Nozzles ...... ...................................................................46 Descriptio n of Alternate Simplified ASME Sect. VIII Div. 2 Nozzle Analysis ............... ...............47 Simplified ASME Sect. VIII Div. 2 Elastic Nozzle Analysis..... .....................................................48 Inclusion of Missing Mas s Correction ................................................................... .....................................49 References ............................. ................................................................................ ..........................52 Fatigue Analysis Using CAESAR II................... ................................................................................ ........54 Fatigue Basics....................................................... ...........................................................................54 Fa tigue Analysis of Piping Systems ............................................... .................................................55 Static Analysis Fatigue Exam ple ............................................................................ .........................56 Fatigue Capabilities in Dynamic Analysis............ ...........................................................................65 Cr eating the .FAT Files .......................................................... .........................................................67 Calculation of Fatig ue Stresses..................................................................... ...................................68 Pipe Stress Analysis of FRP Piping ....... ................................................................................ .....................70 Underlying Theory ...................................... ................................................................................ ....70 FRP Analysis Using CAESAR II ............................................ ........................................................85 Code Compliance Consi derations....................................................................... ........................................93 General Notes for All Codes ......... ................................................................................ ..................93 Code-Specific Notes ....................................... ................................................................................ .98 Local Coordinates .......................................................... ...........................................................................127 O

ther Global Coordinate Systems ................................................. ................................................128 The Right Hand Rule......... ................................................................................ ............................128 Pipe Stress Analysis Coordinate Systems......... .............................................................................130 Defining a Model............................................................... ............................................................133 Using Local Coor dinates ........................................................................ .......................................135 CAESAR II Local Coordinate Definition s .............................................................................. ......136 Applications - Utilizing Global and Local Coordinates................. ................................................140 Transforming from Global to Local .......................................................................... ....................146 Frequently Asked Questions.............................. ............................................................................147 Chapter 7: Miscellaneous Processors 1 Accounting...................................................................... ..............................................................................2 Accounting File Structure....................................................... ...........................................................8

Contents 9 Batch Stream Processing ........................................................ ......................................................................9 CAESAR I I Fatal Error Processing ....................................................... .....................................................11 Chapter 8: Interfaces 1 Overview of CAESAR II Interfaces ............................................... ..............................................................2 CAD Interfaces . ................................................................................ ............................................................4 CADWorx/PIPE Link. ................................................................................ .......................................4 DXF AutoCAD Interface.................. ................................................................................ .................4 CADPIPE Interface ........................................... ................................................................................ 5 ComputerVision Interface ..................................................... ..........................................................24 Intergraph Interfac e .............................................................................. ...........................................26 PRO-ISO Interface ................ ................................................................................ ..........................64 PCF Interface...................................... ................................................................................ .............72 Generic Neutral Files .......................................... ................................................................................ ........74 CAESAR II Neutral File Interface .................................... ..............................................................74 Data Matrix Int erface.......................................................................... .............................................94 Computational Interfaces ....... ................................................................................ .....................................95 LIQT Interface.......................... ................................................................................ .......................95 PIPENET Interface .................................... ................................................................................ ....100 Data Export to ODBC Compliant Databases ................................ ............................................................102 DSN Setup ...... ................................................................................ ...............................................102 Controlling the Data Export . ................................................................................ .........................105 Data Export Wizard ................................ ................................................................................ .......106 Chapter 9: File Sets 1 CAESAR II File Guide ........................................................... ......................................................................2 CAESAR I I Operational (Job) Data Files.................................................. .................................................14 Chapter 10: Update History

1 CAESAR II Initial Capabilities (12/84).......................................... ..............................................................2 CAESAR II Versio n 1.1S Features (2/86) ......................................................... ...........................................3 CAESAR II Version 2.0A Features (10 /86) ........................................................................... ......................4 CAESAR II Version 2.1C Features (6/87).................. ................................................................................ ..5 CAESAR II Version 2.2B Features (9/88)...................................... ..............................................................6 CAESAR II Versio n 3.0 Features (4/90) .......................................................... ............................................7 CAESAR II Version 3.1 Features (11 /90) ........................................................................... .........................8 Graphics Updates..................................... ................................................................................ ..........8 Rotating Equipment Report Updates .................................. ...............................................................8 WRC 107 Updates ................................................................................ .............................................8 Miscellaneous Modifications...... ................................................................................ .......................8 CAESAR II Version 3.15 Features (9/91) ................ ................................................................................ ....9 Flange Leakage and Stress Calculations.................................... ........................................................9 WRC 297 Local Stress C alculations..................................................................... .............................9 Stress Intensification Factor Scratchpad......... ................................................................................ ...9 Miscellaneous ............................................................. .......................................................................9 CAESAR II Version 3.16 Features (12/91) ............................................... .................................................10 CAESAR II Version 3.17 Featu res (3/92) ..................................................................... .............................11 CAESAR II Version 3.18 Features (9/92) ......... ................................................................................ .........12 Codes and Databases ................................................ .......................................................................12

10 Contents Interfaces Added....................................................... .......................................................................12 Miscel laneous Changes ................................................................ ...................................................12 CAESAR II Version 3.19 Fea tures (3/93) ................................................................... ...............................14 CAESAR II Version 3.20 Features (10/93) ...... ................................................................................ ..........15 CAESAR II Version 3.21 Changes and Enhancements (7/94) ............ .......................................................16 CAESAR II Version 3.22 Changes & Enhancements (4/95).................................................. ....................18 CAESAR II Version 3.23 Changes (3/96) ................... ...............................................................................2 0 CAESAR II Version 3.24 Changes & Enhancements (3/97).......................... ............................................21 CAESAR II Version 4.00 Changes an d Enhancements (1/98) .......................................................... .........24 CAESAR II Version 4.10 Changes and Enhancements (1/99) ............. ......................................................25 CAESAR II Version 4.20 Changes and Enhancements (2/00) ................................................ ...................26 CAESAR II Version 4.30 Changes and Enhancements (3/01) ... ................................................................27 CAESAR II Ver sion 4.40 Features ............................................................. ................................................28 CAESAR II Version 4.40 Techni cal Changes and Enhancements ( 5/02)............................................ ......29

1 CHAPTER 1 Introduction In This Chapter Overview ....................................................................... ..............2 Program Support / User Assistance .............................. ...............3 COADE Technical Support........................................ .................4

2 CAESAR II Technical Reference Manual Overview This CAESAR II Technical Reference Guide is the reference manual for CAESAR II. It presents the theory behind CAESAR II operations, and explains why certain tas ks are performed. Users are urged to review the background material contained in this manual, especially when applying CAESAR II to unfamiliar types of analysis . Chapter 2 (see "Configuration and Environment" on page 1) discusses the config uration of CAESAR II and the resulting environment. This includes language suppo rt and program customization. In addition to the COADE supplied routines, severa l third-party diagnostic packages are also mentioned. Chapter 3 (see "Piping Scr een Reference" on page 1), Piping Input Reference, contains images of program ge nerated screens, and explains each input cell, menu option, and toolbar button. Also discussed in detail is the Plot Screen, which displays the input model grap hically. Chapter 4 (see "Structural Steel Modeler" on page 1) examines the Struc tural Steel Modeler and describes all commands, toolbar buttons, menu items, and input fields. Chapter 5 (see "Controlling the Dynamic Solution" on page 1) disc usses the Dynamic Input and Control Parameters: each input cell, toolbar button, and menu item is examined. The purpose and effects of the various Dynamic Contr ol Parameters are detailed. Chapter 6 (see "Technical Discussions" on page 1) co ntains theoretical overviews of various technical methods used in CAESAR II. Bot h common and advanced modeling techniques are covered. Chapter 7 (see "Miscellan eous Processors" on page 1) provides information regarding a few miscellaneous a uxiliary processors. Chapter 8 (see "Interfaces" on page 1) details interfaces b etween CAESAR II and other programs. Chapter 9 (see "File Sets" on page 1) prese nts a list of files associated with CAESAR II. Chapter 10 (see "Update History" on page 1) lists the CAESAR II update history.

Chapter 1 Introduction 3 Program Support / User Assistance COADE s staff understands that CAESAR II is not only a complex analysis tool but als o, at times, an elaborate process one that may not be obvious to the casual user. Wh ile our documentation is intended to address the questions raised regarding pipi ng analysis, system modeling, and results interpretation, not all the answers ca n be quickly found in these volumes. COADE understands the engineer s need to produc e efficient, economical, and expeditious designs. To that end, COADE has a staff of helpful professionals ready to address any CAESAR II and piping issues raise d by users. CAESAR II support is available by telephone, e-mail, fax, and the in ternet; literally hundreds of support calls are answered every week. COADE provi des this service at no additional charge to the user. It is expected, however, t hat questions focus on the current version of the program. Formal training in CA ESAR II and pipe stress analysis is also available from COADE. COADE schedules r egular training classes in Houston and provides in-house and open attendance tra ining around the world. These courses focus on the expertise available at COADE mo deling, analysis, and design.

4 CAESAR II Technical Reference Manual COADE Technical Support Phone: 281-890-4566 Fax: 281-890-3301 E-mail: techsupport@coade.com WEB: www.coa de.com (http://www.coade.com/c2articles/c2_faq_ web.html)

1 CHAPTER 2 Configuration and Environment In This Chapter Generation of the CAESAR II Configuration File ......................2 Computati on Control...................................................................3 S IFs and Stresses................................................................ .........9 Geometry Directives.................................................. ..................18 Plot Colors................................................ ...................................21 FRP Pipe Properties ...................... ..............................................24 Database Definitions .......... .........................................................27 Miscellaneous....... .......................................................................30 Set/Ch ange Password .................................................................. 33 Units File Operations ....................................................... ...........34 Convert Input to New Units ....................................... .................37 Material Database........................................... .............................38

2 CAESAR II Technical Reference Manual Generation of the CAESAR II Configuration File Each time CAESAR II starts, the configuration file caesar.cfg is read from the c urrent data directory. If this file is not found in the current data directory, the installation directory is searched for the configuration file. If the config uration file is not found, a fatal error will be generated and CAESAR II will te rminate. The configuration or setup file contains directives that dictate how CA ESAR II will operate on a particular computer and how it will perform a particul ar analysis. The caesar.cfg file is generated by selecting TOOLS/CONFIGURE/SETUP (or the Configure button from the toolbar) from the CAESAR II Main Menu. Note: You must click the Exit w/Save button on the bottom of the Configure/Setup windo w to create a new configuration file or to save changes to the existing configur ation file. The configuration program produces the Computation Control (on page 3) window. Use the tabs to navigate to the appropriate configuration spreadsheet s. Important: The caesar.cfg file may vary from machine to machine and many of the setup directives modify the analysis. Do not expect the same input file to produ ce identical results between machines unless the setup files are identical. It i s advised that a copy of the setup file be archived with input and output data s o that identical reruns can be made. The units file, if modified by the user, wo uld also need to be identical if the same results are to be produced. The follow ing section explains the CAESAR II setup file options. They are grouped as they appear when chosen from the tabs on the Configure window.

Chapter 2 Configuration and Environment 3 Computation Control Computational Control Configuration Settings Use Pressure Stiffening This flag enables CAESAR II to include pressure-stiffening effects in those code s that do not explicitly require its use. In these cases pressure-stiffening eff ects will apply to all bends, elbows, and both miter types. In all cases, the pr essure used is the maximum of all pressures defined for the element. Missing Mass ZPA The default for this option is Extracted, which means that CAESAR II will use th e spectrum value at the last extracted mode. Changing this value to SPECTRUM instructs CAESAR II to use the last spectrum value as the ZPA for the missing mass comput ations. Bend Axial Shape For bends 45 degrees or smaller, a major contributor to deformation can be the a xial displacement of the short-arched pipe. With the axial shape function disabl ed this displacement mode is ignored and the bend will be stiffer.

4 CAESAR II Technical Reference Manual

Rod Tolerance (degrees) The angular plus-or-minus permitted convergence error. Unless the change from it eration n to iteration n+1 is less this value, the rod will NOT be converged. The CAESAR II is 1.0 degree. For systems subject to large horizontal displacements, values of 5.0 degrees for convergence tolerances have been used successfully. Rod Increment (degrees) The maximum amount of angular change that any one support can experience between iterations. For difficult-to-converge problems, values of 0.1 have proven effec tive here. When small values are used, however, the user should be prepared for a large number of iterations. The total number of iterations can be estimated fr om: Est. No. Iterations = 1.5(x)/(r)/(Rod Increment) Where: x - maximum horizont al displacement at any one rod. r - rod length at that support Alpha Tolerance The breakpoint at which CAESAR II decides that the entry in the Temp fields on t he input spreadsheet is a thermal expansion coefficient or a temperature. The de fault is 0.05. This means that any entry in the Temp fields whose absolute magni tude is less than 0.05 is taken to be a thermal expansion coefficient in terms o f inches per inch (dimensionless). Use of this field provides some interesting m odeling tools. If an Alpha Tolerance of 1.1 is set, then an entry in the Temp 2 field of -1 causes the element defined by this expansion coefficient to shrink t o zero length. This alternate method of specifying cold spring is quite useful i n jobs having hanger design with cold spring (see chapter 6 (see "Technical Disc ussions" on page 1) for more details regarding Cold Spring). Ambient Temperature If 0.0 is entered here, the default ambient temperature for all elements in the system is (degrees ^07) . If this does not accurately represent the installed, o r zero expansion strain state, then enter a different value in this field. Friction Stiffness Friction restraint stiffness. The default is 1E6 lb/in. This value is used when a friction restraint is "nonsliding." In the "non-sliding" state, stiffnesses ar e inserted in the two directions perpendicular to the restraint s line of action and opposing any sliding motion. This is the first parameter that should be adjuste d to help a slowly converging problem where friction is suspected. Lower stiffne ss values permit more "non-sliding" movement, but given the indeterminate nature of the friction problem in general, this error is not considered crucial.

Chapter 2 Configuration and Environment 5 Friction Normal Force Variation This tolerance, default of 0.15, or 15 percent, is the amount of variation in th e normal force that is permitted before an adjustment will be made in the slidin g friction force. This value normally should not be adjusted. Friction Angle Variation Friction sliding angle variation. The default is 15 degrees. This parameter had more significance in versions prior to 2.1. This parameter is currently only use d in the first iteration when a restraint goes from the non-sliding to sliding s tate. All subsequent iterations compensate for the angle variation automatically . Friction Slide Multiplier This is an internal friction sliding force multiplier and should never be adjust ed by the user unless so directed by a member of the COADE/CAESAR II support sta ff. Coefficient of Friction (Mu) The value specified here is applied by default as the coefficient of friction to all translational restraints. Specifying a value of zero, the default, means th at no friction is applied. WRC-107 Version This directive sets the Version of the WRC-107 bulletin used in the computations . Valid options are: August 1965 March 1979 March 1979 with the 1B1-1 and 2B-1 o ff axis curves (default) WRC-107 Interpolation Method The curves in WRC Bulletin 107 cover essentially all applications of nozzles in vessels or piping; however, should any of the interpolation parameters i.e., U, Beta, etc. fall outside the limits of the available curves then some extension o f the WRC method must be used. The default is to use the last value in the parti cular WRC table. Alternatively, the user may control this extensions methodology interactively. This causes the program to prompt the user for curve values when necessary. Incore Numerical Check Enables the in-core solution module to test the stability of the solution for th e current model and loadings. This option, if enabled, adds the solution of an e xtra load case to the job stream.

6 CAESAR II Technical Reference Manual Decomposition Singularity Tolerance The default value is 1.0 e+10. CAESAR II checks the ratio of off-diagonal coeffi cients to the on-diagonal coefficient in the row. If this ratio is greater than the decomposition singularity tolerance, then a numerical error may occur. This problem does not have to be associated with a system singularity. This condition can exist when very small, and/or long pipes are connected to very short, and/o r large pipes. The out-ofcore solution will, however, stop with a singularity me ssage. This solution abort will prevent any possibility of an errant solution. T hese solutions have several general characteristics: When machine precision erro rs of this type occur they are very local in nature, affecting only a single ele ment or very small part of the model, and are readily noticeable upon inspection . The 1E10 limit can be increased to 1E11 or 1E12 and still provide a reasonable check on solution accuracy. Any solution computed after this limit has been inc reased should always be checked closely for reasonableness. At 1E11 or 1E12 the number of significant figures in the local solution has been reduced to two or three. The 1E10 limit can be increased to 1E20 or 1E30 to get the job to run, but the u ser should remember that the possibility for a locally errant solution exists wh en stiffness ratios are allowed to get this high. Solutions should be carefully checked. Minimum Wall Mill Tolerance (%) Use this directive is to specify the default percentage of wall thickness allowe d for mill and other mechanical tolerances. Note: For most piping codes, this va lue is only used during the "minimum wall thickness" computation. Mill tolerance is usually not considered in the flexibility analysis. By default this value is 12.5, corresponding to a 12.5% tolerance. To eliminate mill tolerance considera tion, set this directive to 0.0.

Chapter 2 Configuration and Environment 7 Bourdon Pressure Select the BOURDON PRESSURE EFFECT from the drop list. The BOURDON EFFECT causes straight pipe to elongate, and bends to "OPEN UP" translationally along a line connecting the curvature end points. If the BOURDON EFFECT is not activated ther e will be no global displacements due to pressure. BOURDON PRESSURE OPTION #1 (TRANSLATION ONLY) includes only translational effect s. BOURDON PRESSURE OPTION #2 (TRANSLATION & ROTATION) includes translational and r otational effects on bends. OPTION #2 may apply for bends that are formed or rol led from straight pipe, where the bend cross section will be slightly oval due t o the bending process. Note: OPTION #1 is the same as OPTION #2 for straight pipe. For elbows, OPTION # 1 should apply for forged and welded fittings where the bend cross section can b e considered essentially circular. Note: The BOURDON EFFECT (translation only) is always considered when FRP pipe i s used, regardless of the actual setting of the BOURDON FLAG. Ignore Spring Hanger Stiffness Enabling this option causes CAESAR II to ignore the stiffness of spring hangers in the analysis. This option is consistent with hand computation methods of spri ng hanger design, which ignored the effects of the springs. Important: COADE rec ommends that this value never be changed. Include Spring Stiffness in Hanger OPE Travel Cases Enabling this option defaults CAESAR II to place the designed spring stiffness i nto the Hanger Operating Travel Case and iterate until the system balances. This iteration scheme therefore considers the effect of the spring hanger stiffness on the thermal growth of the system (vertical travel of the spring). If this opt ion is used, it is very important that the hanger load in the cold case (in the physical system) be adjusted to match the reported hanger Cold Load. Disabling t his option defaults the program to design spring hangers the traditional way.

8 CAESAR II Technical Reference Manual Hanger Default Restraint Stiffness Where hangers are adjacent to other supports or are themselves very close (for e xample where there are two hangers on either side of a trunnion support), the CA ESAR II hanger design algorithm may generate poorly distributed hot hanger loads in the vicinity of the close hangers. Using a more flexible support for computi ng the hanger restrained weight loads often allows the design algorithm to more effectively distribute the system s weight. A typical entry is 50,000; the default v alue is (1.0E12 lb/in). Default Translational Restraint Stiffness This directive defines the value used for non-specified translational restraint stiffnesses. By default this value is assumed to be (1.0E12 lb./in). Default Rotational Restraint Stiffness This directive defines the value used for non-specified rotational restraint sti ffnesses. By default this value is assumed to be (1.0E12 in-lb/deg).

Chapter 2 Configuration and Environment 9 SIFs and Stresses SIFs and Stresses Configuration Settings Default Code The piping code the user designs to most often should go here. This code will be used as the default if no code is specified in the problem input. The default p iping code is B31.3, the chemical plant and petroleum refinery code. Valid entri es are B31.1, B31.3, B31.4, B31.4 Chapter IX, B31.5, B31.8, B31.8 Chapter VIII, B31.11, ASME-NC(Class 2), ASME-ND(Class 3), NAVY505, Z662, BS806, SWEDISH1, SWED ISH2, B31.1-1967, STOOMWEZEN, RCCM-C, RCCM-D, CODETI, Norwegian, FDBR, BS7159, U KOOA, IGE/TD/12, and DNV.

10 CAESAR II Technical Reference Manual Occasional Load Factor The default value of 0.0 tells CAESAR II to use the value that the active piping code recommends. B31.1 states that the calculated stress may exceed the maximum allowable stress from Appendix A, (Sh), by 15% if the event duration occurs les s than 10% of any 24 hour operating period, and by 20% if the event duration occ urs less than 1% of any 24 hour operating period. The default for B31.1 applicat ions is 15%. If 20% is more suitable for the system being analyzed then this dir ective can be used to enter the 20%. B31.3 states, The sum of the longitudinal stre sses due to pressure, weight, and other sustained loadings (S1) and of the stres ses produced by occasional loads such as wind or earthquake may be as much as 1. 33 times the allowable stress given in Appendix A. Where the allowable stress va lue exceeds 2/3 of yield strength at temperature, the allowable stress value mus t be reduced as specified in Note 3 in 302.3.2. The default for B31.3 applications is 33%. If this is too high for the material and temperature specified then a sm aller occasional load factor can be input.

Chapter 2 Configuration and Environment 11 Yield Stress Criterion The 132 column stress report produced by CAESAR II contains a value representati ve of the maximum stress state through the cross section, computed per the indic ated yield criteria theory. CAESAR II can compute this maximum stress (note, thi s is not a Code stress) according to either Von Mises Theory or the Maximum Shea r Theory. The selected stress is computed at four points along the axis normal t o the plane of bending (outside top, inside top, inside bottom, outside bottom), and the maximum value is printed in the stress report. The equations used for e ach of these yield criteria are listed below. If the Von Mises Theory is used, C AESAR II computes the octahedral shear stress, which differs from the Von Mises stress by a constant factor. (For B31.4 Chapter IX, B31.8 Chapter VIII, and DnV this setting controls which equation is used to compute the "equivalent stress". For these three codes, the equations shown in the code are used to determine th e yield criterion, not the standard mechanical stress equations shown below. The se standard mechanical stress equations are used for the other codes addressed b y CAESAR II. ) 3D Maximum Shear Stress Intensity (Default) SI = Maximum of: S1OT - S3OT S1OB S3OB Max(S1IT,RPS) - Min(S3IT,RPS) Max(S1IB,RPS) - Min(S3IB,RPS) Von Mises Stres s (Octahedral) OCT = Maximum of: (S3OB2+S1OB2+(S3OB-S1OB)2)1/2 / 3.0 ((S3IB-RPS) 2+(S3IB-S1IB)2+(RPS-S1IB)2)1/2 / 3.0 (S3OT2+S1OT2+(S1OT-S3OT)2)1/2 / 3.0 ((S3ITRPS)2+(S3IT-S1IT)2+(RPS-S1IT)2)1/2 / 3.0 Where: S1OT=Maximum Principal Stress, O utside Top = (SLOT+HPSO)/2.0+(((SLOT-HPSO)/2.0)2+TSO2)1/2 S3OT=Minimum Principal Stress, Outside Top =(SLOT+HPSO)/2.0- (((SLOT-HPSO)/2.0)2+TSO2) 1/2

12 CAESAR II Technical Reference Manual S1IT=Maximum Principal Stress, Inside Top =(SLIT+HPSI)/2.0+(((SLIT-HPSI)/2.0)2+T SI2) S3IT=Minimum Principal Stress, Inside Top =(SLIT+HPSI)/2.0- (((SLIT-HPSI)/2 .0)2+TSI2) S1OB=Maximum Principal Stress, Outside Top =(SLOB+HPSO)/2.0+ (((SLOBHPSO)/2.0)2+TSO2) 1/2 1/2 1/2 S3OB=Minimum Principal Stress, Outside Bottom =(SLOB+HPSO)/2.0- (((SLOB-HPSO)/2. 0)2+TSO2) 1/2 S1IB=Maximum Principal Stress, Inside Bottom =(SLIB+HPSI)/2.0+ (((SLIB-HPSI)/2.0 )2+TSI2) 1/2 S3IB=Minimum Principal Stress, Inside Bottom =(SLIB+HPSI)/2.0- (((SLIB-HPSI)/2.0 )2+TSI2) RPS=Radial Pressure Stress, Inside HPSI=Hoop Pressure Stress (Inside, f rom Lame s Equation) HPSO=Hoop Pressure Stress (Outside, from Lame s Equation) SLOT=Long itudinal Stress, Outside Top SLIT=Longitudinal Stress, Inside Top SLOB=Longitudi nal Stress, Outside Bottom SLIB=Longitudinal Stress, Inside Bottom TSI=Torsional Stress, Inside TSO=Torsional Stress, Outside 1/2 B31.3 Sustained Case SIF Factor B31.3 Code Interpretation 1-34 dated February 23, 1981 File: 1470-1 states that for sustained and occasional loads an SIF of 0.75i, but not less than 1.0 may be used. This setup directive allows the user to enter his/her own coefficient. Th e default is 1.0. To comply with this interpretation the user would enter 0.75. B31.3 Code Interpretation 6-03 dated December 14, 1987 permitted users to ignore the stress intensification for sustained and occasional loads.To comply with th is interpretation, the user would enter 0.0.

Chapter 2 Configuration and Environment 13 B31.3 Welding and Contour Insert Tees Meet B16.9 This flag controls the "assumption" that the geometry of B31.3 welding and conto ur insert tees (sweepolets) meet the dimensional requirements of the code, and c an be classified as B16.9 tees. The default setting for this directive is "NO", which causes the program to use a flexibility characteristic of 3.1*T/r, as per the A01 addendum. Selecting this checkbox, allows the program to assume that the fitting geometry meets the requirements of Note 11, introduced in the A01 adden dum, and a flexibility characteristic of 4.4*T/r will be used. Note: In order to match runs made with CAESAR II prior to Version 4.40, this checkbox must be sel ected. Prior to Version 4.40, CAESAR II always used a flexibility characteristic of 4.4*T/r. Allow User's SIF at Bend This feature was added for those users that wished to change the stress intensif ication factor for bends. Previously this was not permitted, and the code define d SIF was always used. If the user enables this directive, he may override the c ode s calculated SIF for bends. The user entered SIF acts over the entire bend curva ture and must be specified at the TO end of the bend element. The default is off. Use WRC329 This directive activates the WRC329 guidelines for all intersections, (not just for reduced intersections). The recommendations made by Rodabaugh in section 5.0 of WRC329 will be followed exactly in making the stress calculations for inters ections. Every attempt has been made to improve the stress calculations for all codes, not just the four discussed in Rodabaugh s paper. Users not employing either B31.1, B31.3 or the ASME NC or ND codes, and who wish to use WRC329 are encourag ed to contact COADE for additional information. Throughout this document WRC330 and WRC329 are used synonymously (330 was the draft version of 329). When finall y published, the official WRC designation was 329. Use Schneider This directive activates the Schneider reduced intersection assumptions. It was because of observations by Schneider that much of the work on WRC 329 was starte d. Schneider pointed out that the code SIFs could be in error when the d/D ratio at the intersection was less than 1.0 and greater than 0.5. In this d/D range t he SIFs could be in error by a factor as high as 2.0. Using the Schneider option in CAESAR II results in a multiplication of the out of plane branch stress inte nsification by a number between 1 and 2 when the d/D ratio for the intersection is between 0.5 and 1.0. For B31.1 and other codes that do not differentiate betw een in and out-of-plane SIFs the multiplication will be used for the single stre ss intensification given. All Cases Corroded A recent version of the B31.3 piping code mentioned reducing the section modulus for sustained or occasional stress calculations by the reduction in wall thickn ess due to corrosion. Several users have interp