PIPING STRESS ANALYSISBY CAESAR-II SOFTWARE

FDC PIPING

CAESAR MODELING

ANALYSIS

REPORT

WHAT MAKES PIPING CRITICAL?

• Temperature

• Pressure

• Occasional loads (Seismic & Wind)

• Dynamics of the flowing fluid

FDC PIPING

WHAT CAUSES STRESS IN THE PIPE?

• Live and Dead load (Piping component, Insulation,

Flowing medium etc.).

• Line pressure

• Restraining of pipe expansion or Temperature gradient

• Discharge reaction (E.g. Relief valves)

• Seismic / Wind load

• Dynamics of flowing fluid.

FDC PIPING

Cont….

WHY STRESS ANALYSIS IS TO BE DONE?

To ensure that all stresses in the piping system are

within allowable limits.

To limit the loads on the equipment nozzle.

To limit the thermal displacement and sagging

To limit the loads on the supporting structures &

flanged joints.

To avoid excessive piping vibration

FDC PIPING

WORK FLOW DIAGRAM FOR STRESS GROUP

Piping Team

Process Dept.

Stress AnalysisTeam

Stress AnalysisReport

Civil Dept.Mechanical

Dept.

Site/ Field

InstrumentationDept.

P&IDLDT

SoilCharacteristics

Civil andStructural

Support loadings

Supports Loadingsfor pipe support

selection, pipedisplacements at

operating temp.SAQ,

alongwithStress

Isometricsand other

data

EquipmentG.A.'s

Cleat Loads, Nozzleloads if more than

allowables

Fabricationand Erection

Isometric

Spring, SPS,Specials datasheets, Site problemresolutions, AuditReports

Instrument data

INPUT FOR STRESS ANALYSIS

Stress Isometrics

LDT / P&ID

Equipment G.A.Drawing

Instrument(e.g.PSV/control valve) data sheet

FDC PIPING

SOFTWARE USED

CAESAR II 4.5

Piping Stress Analysis Software

FDC PIPING

In-house software (Tracking system)

SATS

SSTS

CAESAR CONVERT

MODELLING

Piping Components

Piping

Equipments

Restraints

FDC PIPING

Cont….

FDC PIPING

Cont….

NODE SKETCH

STRESS ISO MARKUP

Caesar Modelling

CAESAR INPUT SPREADSHEET

Batch Run

Allowable Stress At Hot Condition

Allowable Stress At Cold Condition

Start Run

Material Selection

Geometry

RESTRAINT MODELLING

SPRING MODELLING

CONSTANT SPRING

INPUT SPREADSHEET

FORCE MODELLING

BEND MODELLING

SEISMIC FORCE INPUT

PROCEDURE FOR PUMP LINE ANALYSIS

PROCEDURE FOR PUMP LINE ANALYSIS

REQUIRED DOCUMENTS

? Pump line ISO, Pump vendor drg, allowable nozzle Load, P& ID, and LDT. In the

absence of allowable load in vendor drg, twice of API-610 values are used. CAESAR axis

system should match with vendor drg or API-610 for comparing nozzle allowable loads and

moments.

PUMP MODELING IN CAESAR-II

Most commonly used centrifugal pumps are:

1. End suction – Top discharge

2. Top suction – Top discharge

3. Side suction – Side discharge

For above mentioned pumps detail modeling procedure in CAESAR-II is discussed as

below

1. End suction – Top discharge

Referring to Fig.1, node marking 1-2 shows nozzle flange with given flange rating

as “rigid” element. Node 2-3 shows nozzle standby with pipe element (dia equal to pump

impeller dia and thickness equal to pipe wall thickness) as rigid element with zero weight

from flange welding joint to pump impeller center line.

Restraints –

1) The pipe flange to be get anchored as C- Node with pump flange to get

nozzle load due to piping reaction. This load value should be less than allowable values.

2) Rigid element at Impeller C/L to be get anchored i.e. anchor at node3.

PROCEDURE FOR PUMP LINE ANALYSIS

  2. Top suction – Top discharge & 3. Side suction – Side discharge Referring to Fig.2 & 3, node marking 1-2 shows nozzle flange with given flange rating as “rigid” element. Node 2-3

shows nozzle standby with pipe element (Dia equal to pump impeller dia and thickness equal to pipe wall thickness) as rigid element with zero weight from flange welding joint to pump impeller center line. Node 3-4 shows rigid element with zero weight up to center line of the pump.

Restraints – 1) The pipe flange to be get anchored as C- Node with pump flange to get nozzle load due to piping reaction. This load value

should be less than allowable values. 2) Rigid element at pump C/L to be get anchored i.e. anchor at node4.    

PROCEDURE FOR PUMP LINE ANALYSIS

ANALYSIS

FDC PIPING

STATIC ANALYSIS

DYNAMIC ANALYSIS

TYPES OF STRESSES

FDC PIPING

PRIMARY

SECONDARY

TYPES OF LOAD

FDC PIPING

Sustain Load

Occasional Load

Thermal Load

Hydro Test Load

LOAD CASE DEFINATION

L1 WW + HP (HYD)

L2 W + T1 + P1 + H (OPE)

L3 W + T2 + P1 + H (OPE)

L4 W + P1 + H (SUS)

L5 L2 – L4 (EXP)

L6 L3 – L4 (EXP)

FDC PIPING

LOAD CASE DEFINATION

FDC PIPING

L1 W + T1 + P1 + H (OPE)

L2 W + P1 + H (SUS)

L3 U1 (OCC)

L4 U2 (OCC)

L5 L2 + L3 (OCC)

L6 L2 + L4 (OCC)

CAESAR LOAD CASES

DESIGN TEMP. LOAD CASE

OPERATING TEMP. LOAD CASE

PROCEDURE FOR PUMP LINE ANALYSIS

When two or more pumps are used in a system then from stress analysis point of view the different load cases are made. Like,

♦ Both pump operating.

♦ One pump operating & one stand by.

(This point to be get discussed with process, what will be the requirement, whether “at any moment only one pump will operate, for more than two pump case”)

♦ Hot Cold analysis to be done at design and operating temperature.

♦ For the pump, which is not operating, ambient temperature should be considered from Tee point ► When two pumps are present in the system hot cold cases can be made as below (Refer Fig. 4).

LOAD CASES FOR PUMP LINE STRESS ANALYSIS Load cases for the pump connected lines are discussed below.1. Hot Cold Load case:

PROCEDURE FOR PUMP LINE ANALYSIS

Case 1: When both pumps are in operating condition, provide design and operating temperature for node 10-20-30-40-A & 20-50-60-B

Case 2: When pump “A” is operating and pump “B” is cold, provide design and operating temperature for node 10-20-30-40-A and ambient temperature for 20-50-60-B.

Case 3: When pump “B” is operating and pump “A” is cold, provide design and operating temperature for node 10-20-50-60-B and ambient temperature for 20-30-40-A. ► When three pumps are present in the system hot cold cases can be made as below (Refer Fig. 5).  

PROCEDURE FOR PUMP LINE ANALYSIS

CASE6: W+P1+T5 (OPE) ………Pump “A” at operating temp and Pump “B” standby.CASE7: W+P1+T6 (OPE) ………Pump “B” at operating temp and Pump “A” standby.CASE8: W+P1 (SUS)CASE9: WNC (SUS)CASE10: L2-L8 (EXP) CASE11: L3-L8 (EXP) CASE12: L4-L8 (EXP)CASE13: L5-L8 (EXP)CASE14: L6-L8 (EXP)CASE15: L7-L8 (EXP)

♦ For load case no 2, 3, 4, 5, 6,7and 8 pump nozzle load is checked and it should be within acceptable limit as specified by vendor or API 610.

♦ For load case no 1, 8, 10, 11,12,13,14 and 15 stress value is checked and it should be less than allowable stress as specified by relevant code.

♦ For load case no 9 (WNC case) deflection is checked at pipe flange for cold alignment case as discussed in earlier topic of WNC load case.B. Load Cases for Static Analysis (Three Pumps A, B & C)CASE1: WW+HP (HYD)CASE2: W+P1+T1 (OPE) …Three pumps at design temperature. CASE3: W+P1+T2 (OPE) …Three pumps at operating temperature. CASE4: W+P1+T3 (OPE) ….Pump “B&C” at design temp and Pump “A” standby.CASE5: W+P1+T4 (OPE) …..Pump “A&C” at design temp and Pump “B” standby.CASE6: W+P1+T5 (OPE) …..Pump “A&B” at design temp and Pump “C” standby.CASE7: W+P1+T6 (OPE) …..Pump “B&C” at operating temp and Pump “A” standby.CASE8: W+P1+T7 (OPE) …..Pump “A&C” at operating temp and Pump “B” standby.CASE9: W+P1+T8 (OPE) …..Pump “A&B” at operating temp and Pump “C” standby.CASE10: W+P1 (SUS)CASE11: WNC (SUS) CASE12: L2-L10 (EXP) CASE13: L3-L10 (EXP) CASE14: L4-L10 (EXP)

PROCEDURE FOR PUMP LINE

Case 1: When three pumps are in operating condition, provide design and operating temperature for whole system.

Case 2: When pump “A” is cold and pump “B & C” are operating, provide design and operating temperature to node 10-20-30-70-B & 20-50-60-C and ambient temperature for 30-40-80-A.

Case 3: When pump “B” is cold and pump “A & C” are operating, provide design and operating temperature to node 10-20-30-40-80-A & 20-50-60-C and ambient temperature for 30-70-B

Case 4: When pump “C” is cold and pump “A & B” are operating, provide design and operating temperature to node 10-20-30-40-80-A & 30-70-B and ambient temperature for 20-50-60-C.2. WNC (Weight No Content) Load case: The basic philosophy for “WNC” is by what magnitude the piping flange displaced at the mating point while cold alignment. For “WNC” case, make the pump flange anchor node free and replace the spring support to rigid support. Go in load case spread sheet, drag the “WNC” from side menu to load case row and select “Sustain case”. Run the case and get the displacement at the pump nozzles, this displacement should be less than 1mm (or consult mechanical department to get allowable deflection). 3. Load Cases in CAESAR-II for two pump connected system Load cases for stress analysis of two pump connected piping system are discussed below. Same philosophy is applicable for more than two pump connected system. Abbreviation: W = Weight; T= Temperature; HP = Hydro Pressure; WW = Water Filled Weight; WNC = Weight No Contents; P = Design Pressure. U1 = Uniform load (NS Seismic); U2 = Uniform load (EW Seismic); A. Load Cases for Static Analysis (Two Pumps A & B)CASE1: WW+HP (HYD)CASE2: W+P1+T1 (OPE) ………Both pumps at design temperature.CASE3: W+P1+T2 (OPE) ………Both pumps at operating temperature. CASE4: W+P1+T3 (OPE) ………Pump “A” at design temp and Pump “B” standby.CASE5: W+P1+T4 (OPE) ………Pump “B” at design temp and Pump “A” standby.

CAESAR OUT PUT

REPORT INTERPRETATION Displacement

Restraints

Restraints Summary

Global Element Forces

Local Element Forces

Stresses

Sorted Stress

Code ComplianceFDC PIPING

REPORT INTERPRETATION

Hanger Table

Hanger Table W/Text

Input Echo

Miscellaneous Data

Load Case Report

Warnings

FDC PIPING

OUTPUT SHEET

REPORTING

Stress Analysis Query Front Sheet

Caesar Title Sheet

Stress Isometrics with markup

Load summary sheet

Spring / Bellow data sheet

SPS drawing

Caesar Load summary sheetFDC PIPING

Stress Analysis Query Report

Job No. : 22960

Job Title : Jamnagar Refinary Project -

Complex : Coke Unit : 371 Title : QYI/COK

Description : Tie-In for Heater

Package No. : Coke-371-041-00 Rev.: 0 Caesar File name : KA041A00

Analyst : rajeshr Date of issue : 18/11/2003

Isometrics : A15-371-PA017, A09-

Reason for analysis : Others

Ref. Doc. : Enclosed - Stress Isometrics - Attached sheets

Caesar Dump - Attached

Load Summary Report - Attached

Caesar front sheet - for ref. Attached

Spring Report -

Spring Datasheets -

SPS drawing -

Pump/Equipment datasheet/drawing - Attached

Copy of LDT - Attached

Stress Remarks: Line Checked for Tie -in to the existing line.

SAQ SHEET

CAESAR DUMP

RESTRAINT OUTPUT

User is given an unlocked cell (F53) to write any special comment / note.

MAINTENANCE

EL1-EL2=1500 mm

SPRING DETAILS File name: Calc No.: Node No.:

LINE NO.: TYPE: B SIZE: FIG:

ISO OR GA NO.: BOTTOM CONNECTION NO.:

INSTALLED LOAD: KN PIPE SIZE: PIPE MATERIAL:

OPERATING LOAD: KN EL1.: EL2.: EL3.:

TEST LOAD: KN DESIGN TEMPERATURE: oC

TRAVEL (+ UP / - DOWN): mm P/SUPP TYPE: K N/mm

TRAVEL (AXIAL): mm TRAVEL (LATERAL): mm

MANUFACTURER: MATCODE % VARIABILITY 0.6

NOTES:

Remark: FOR MAINTNANCE (Line 951- WB- 012- 10")

GO TO

SARATHI

49137

32.626 10"

F1951-951-WB012A

32.812 47637

MAINTECE

48.939

BAWB401D

CS

VS2951-WB401-10"-EC62EM-HC25

1820

150

16

1 SS

NA-0.560

1.000

13-12-2005 Issued for Construction RVB

1.000

QUANTITY REQUIRED

1

REV. DATEDES'N ENGR

CHKD BY

REVISION

PIPE SUPPORT STANDARD

VARIABLE SPRINGS1951Y-SPR-00422960

REVDRAWING NoJOB No

FIELD DESIGN CELL

APPD BY

PROJ. ENGR

CLIENT

0 01-09-2003 Issued for Construction

BOTTOM CONNECTION''B'' TYPE HANGER

MGC RPL

SS MGC RPLRRR

6

333.2

CL

EL 1

(U/S STL.)

RELIANCE INDUSTRIES LIMITED JAMNAGAR REFINERY PROJECT

1. All welds to be 6mm CFW unless otherwise noted.2. All make-up components to be supplied by the manufacturer.3. All bottom connection material to be suited with pipe material.4. Elevations (EL) are in mm.

CL

CLEL.2

SPRING DATASHEET

SPS DRAWING

BELLOW DATASHEET

Reliance Engineering Associates Private Ltd.

Load Summary Chart

Fx Fy Fz Fx Fy Fz Fx Fy Fz Fx Fy Fz Fx Fy Fz10 -3026 -15458 -11511 -11585 -12790 -39967 -147 -14754 704 -3026 -8704 -9998 -2474 -9314 -11511

120 -283 -19172 814 -283 -13086 556 20 -17646 519 -83 -635 172 -283 -2080 556130 -689 -11710 3445 -647 -13980 3174 299 -3528 322 -689 -11710 3445 -647 -10799 3174140 -5500 -26565 7648 -5109 -23280 7567 -898 -21080 223 -5500 -20273 7648 -5109 -20428 7567170 1326 -27275 6542 704 -23156 6541 1035 -21389 -427 742 -21947 6542 704 -21930 6541210 -4914 -22514 -967 -4895 -18103 -967 -169 -17668 553 -4914 -16628 -861 -4895 -16631 -967220 -4877 -12546 -6954 -4831 -11815 -28705 -95 -9839 -22 -4877 -9512 -6954 -4831 -9548 -6784230 -3838 -16219 217 -3833 -13389 217 -54 -12723 4 -3838 -12808 193 -3833 -12798 217240 9691 -15425 2121 50488 -12233 2005 -31 -12099 -1 9691 -12077 2121 9349 -12079 2005250 3532 -15003 -4500.9 3531 -11814 -66 -18 -11768 -3530.4 3532 -11774 -60 3531 -11774 -66260 4123 -17525 -5257.5 4123 -13755 -10608 -11 -13746 -4123.8 4123 -13745 -52 4123 -13745 -56270 1440 -6118 -1835.4 1440 -4801 -14 -8 -4799 -1439.7 1440 -4799 -14 1440 -4799 -14580 -6309 -3048 1893 -30719 -2294 1820 -143 -2778 -83 -6309 2 1893 -6087 -210 1820590 1086 -3479 -323 1048 -3593 -2344 -45 -2643 29 1086 -3479 -323 1048 -3402 -288600 713 -3097 -8 713 -2467 -1 -15 -2599 -8 707 -2356 -2 713 -2378 -1610 998 -3515 357 992 -3094 2096 -7 -2908 2 998 -3010 357 992 -3002 350640 745 -3056 -916.8 745 -2561 -36 1 -2548 -1 743 -2480 -34 745 -2485 -36650 -1011.3 -3371 -1011.3 952 -2912 -2186 -839.4 -2798 -839.4 958 -2884 -334 952 -2877 -322660 -959.4 -3198 6 728 -2439 6 1 -2658 -1 721 -2405 5 728 -2426 6670 1084 -3614 44 1060 -3551 1916 1 -2681 3 1084 -3614 44 1060 -3534 37680 279 -3285 -16 279 -986 7 4 -2729 -13 222 -742 6 279 -929 7690 17 -3298 65 0 1230 1740 14 -2791 51 0 0 21 0 0 17805 662 -12263 3619 4126 -19457 3619 -45 -8552 -192 662 -12263 3619 609 -12232 3619875 334 -10434 -3757 334 -17659 -8978 52 -7854 164 149 -10434 -3161 334 -10185 -3757960 2678 -2340 -532 4886 2336 -510 91 -1943 -120 2678 603 -532 2495 548 -510985 -90 -1900 -563 -70 -2389 -481 -76 -1554 -460 -69 -1599 -475 -70 -1621 -481990 -1484 -3195 -3820 -1291 -3833 -14357 -58 -2531 220 -1484 -3195 -3754 -1291 -3096 -3820

1000 1461 -3008 699 4403 -2397 623 18 -2517 -172 1461 -925 699 977 -1178 6231100 746 -11349 3322 282 -10415 2670 -39 -5361 94 746 -11349 3322 282 -8949 26701140 -876 -17708 -5240 -734 -15470 -4307 28 -9575 -179 -876 -17708 -5240 -734 -14562 -43071220 -1472 -8969 -800 -1472 -6209 -638 -225 -7491 281 -965 -4179 -800 -1472 -5347 -6381250 -1786 -7238 1407 -1392 -7528 1407 172 -6088 -65 -1786 -7151 1189 -1392 -6596 14071260 -2088 -8217 -1310 -1651 -8135 -1100 -55 -5653 -22 -2088 -8217 -1310 -1651 -8018 -11001270 168 -7976 -503 12594 -5832 -503 -38 -6698 22 0 0 0 168 -1641 -5031299 -954 -12798 -3719 -484 -20930 -3371 130 -8447 -39 -954 -12798 -3719 -484 -11352 -33711410 1262 -3049 729 2191 -12199 8028 -100 -2350 -38 1262 -3049 -380 668 -2981 7291620 1564 -8812 -535 1564 -6172 -256 234 -7358 193 1144 -4211 -535 1564 -5281 -2561640 1896 -7262 1227 1604 -7446 1227 -168 -6108 -61 1896 -7215 1045 1604 -6733 12271650 2137 -8183 -1281 2044 -8373 -1281 56 -5645 -20 2137 -8183 -1209 2044 -8041 -12811660 -240 -7980 -493 -12267 -6298 -493 35 -6701 23 0 0 0 -240 -1521 -4931689 955 -13120 -3818 467 -20978 -3490 -122 -8829 -38 955 -13120 -3818 467 -11736 -34901800 -1259 -3067 1001 -1764 -11820 8638 95 -2342 -39 -1259 -3067 89 -651 -3032 10013010 1246 -7833 1407 757 -11537 1401 -34 -6972 366 1246 -6263 1407 757 -5308 14013070 600 -2164 304 552 -2415 304 -17 -1880 -38 600 -2132 220 552 -2099 3044050 -2495 -12491 2801 -2490 -14246 2801 -1801.8 -6006 -1802 -2495 -12206 2680 -2490 -12491 28014070 -248 -4676 1381 0 1316 0 -167 -3602 1068 0 0 0 0 0 04120 -15837 -31157 -2994 -19092 -11612 -2599 711 -23909 -1135 -15837 -4411 -2994 -9860 -8782 -25994150 16655 0 21194 18228 0 22805 0 0 0 16655 0 21194 10765 0 136464170 4653 -83854 24722 2841 -45483 12902 1619 -27407 -728 4653 -83854 24722 2841 -44038 12902

OperatingNode

Max. Static Max. Composite Occ

14-Jan-06c:\stressout\KB038A001401141157.xls

Sustained Design

Date of Generation:File Location:

LOAD SUMMARY SHEET

FDC PIPING

COMPLETED STRESS ISO

PRACTICAL SESSION DEMONSTRATION OF CAESAR

THANK YOU!!