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CAESAR II is most often used for the mechanical design of new piping
systems. Hot piping systems present a unique problem to the mechanical
engineerthese irregular structures experience great thermal strain that must
be absorbed by the piping, supports, and attached equipment. These
structures must be stiff enough to support their own weight and also flexible
enough to accept thermal growth. These loads, displacements, and stresses can
be estimated through analysis of the piping model in CAESAR II. To aid in this
design by analysis, CAESAR II incorporates many of the limitations placed
on these systems and their attached equipment. These limits are typically
specified by engineering bodies (such as the ASME B31 committees, ASME
Section VIII, and the Welding Research Council) or by manufacturers of pipingrelated equipment (API, NEMA, or Expansion Joint Manufacturers Association EJMA).
Once finished users must click Exit w/Save at the bottom of the
Configure/Setup window to create a new configuration file or to save
changes to the existing configuration file. The configuration program
produces the Computation Control window.
Important: The caesar.cfg file may vary from machine to machine and
many of the setup directives modify the analysis. The units' file, if
modified by the user, would also need to be identical if the same
results are to be produced.
See the next slide for an image of the Computational Control panel.
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 piping code is B31.3, the chemical plant
and petroleum refinery code. Valid entries are B31.1, B31.3, B31.4,
B31.4 Chapter IX, B31.5, B31.8, B31.8 Chapter VIII, B31.11, ASMENC(Class 2), ASME-ND(Class 3), NAVY505, Z662, Z662 Chapter 11,
BS806, SWEDISH1, SWEDISH2, B31.1-1967, STOOMWEZEN, RCCMC, RCCM-D, CODETI, Norwegian, FDBR, BS-7159, UKOOA,
IGE/TD/12, DNV, EN-13480, and GPTC/192.
Occasional Load Factor
B31.3 states, The sum of the longitudinal stresses due to pressure,
weight, and other sustained loadings (S1) and of the stresses
produced by occasional loads such as wind or earthquake may be
as much as 1.33 times the allowable stress given in Appendix A
The default for B31.3 applications is 33%. If this is too high for the
material and temperature specified then a smaller occasional load
factor could be input.
Yield Stress Criterion:
Von Mises Theory or the
Maximum Shear Theory
Bends:
Stiffened
Bends
90-degree Bends
Mitered Bends
Elbows
Restraints:
Expansion Joints
Simple
Bellows with
Pressure Thrust
Tied
Bellows
Universal
Hinged
Slip
Ball
Joints
Joints
Joints
Joints
Hangers:
Single Can
Joints
Gimbal
Anchors
Guides
Limit Stops
Windows
Double-Acting Restraints
Miscellaneous
Reducers
Jacketed Pipe
Bends are defined by the element entering the bend and the element
leaving the bend. The actual bend curvature is always physically at the
TO end of the element entering the bend.
(The element direction is defined from the first node to the second node.)
The input for the element leaving the bend must follow the element
entering the bend. The bend angle is defined by these two elements.
Bend radius defaults to 1 1/2 times the pipe nominal diameter (long
radius), but may be changed to any other value.
Nodes defined in the Angle and Node fields are placed at the given
angle on the bend curvature. The angle starts with zero degrees at the
near-point on the bend and goes to degrees at the far-point of the
bend.
Req = S / [ 2 tan() ]
Where:
Req - equivalent miter bend radius
S - spacing of the miter cuts along the centerline
- code defined half-angle between adjacent miter cuts: = / 2N
And where:
- total bend angle
N - number of cuts
B = S [ 1 - ro / Req ]
Where:
ro - outside radius of pipe cross-section
S < r [ 1 + tan () ]
Where:
S - miter spacing
r - average pipe cross section radius: (ri+ro)/2
- one-half the angle between adjacent miter cuts.
Req = S / [ 2 tan () ]
= / 2N = 90 / [2(4)] = 11.25 deg.
Req = 15.913 / [2 tan (11.25 deg.)] = 40
22.5 deg.
In CAESAR II, widely spaced miters must be entered as
individual, single cut miters, each having a bend radius
equal to:
R = r [1 + cot ()] / 2
R - reduced bend radius for widely spaced miters.
Pipe O. D. = 10.375 in
Pipe Thk. = 0.500 in
Bend Angle = 90
degrees
Cuts = 2
Req = 45 in
Note: The straight pipe section coming into and going out of the bend
must be Req sin ().
The hanger design algorithm will not design hangers that are
completely predefined. Any other data can exist for the spring
location but this data is not used. Entered spring rates and
theoretical cold loads will be multiplied by the number of
hangers at this location. CAESAR II requires the Theoretical
Cold (Installation) Load to pre-define the spring.
Theoretical Cold Load = Hot Load + Travel * Spring Rate
where upward travel is positive.
The basic parameters input into CAESAR II describe the wave height and
period, and the current velocity. The most difficult to obtain, and also the most
important parameters, are:
the drag, Cd
inertia, Cm and
lift coefficients, Cl
Based on the recommendations of API RP2A and DNV (Det Norske Veritas),
values for Cd range from 0.6 to 1.2, values for Cm range from 1.5 to 2.0. Values
for Cl show a wide range of scatter, but the approximate mean value is 0.7. The
inertia coefficient Cm is equal to one plus the added mass coefficient Ca. This
added mass value accounts for the mass of the fluid assumed to be entrained
with the piping element.
In actuality, these coefficients are a function of the fluid particle velocity, which
varies over the water column. In general practice, two dimensionless parameters
are computed which are used to obtain the Cd, Cm, and Cl values from published
charts.
45000 / (dbolt)
where 45,000 psi is a constant and d is the nominal diameter of the bolt
(correction is made for metric units).
This is a rule of thumb tightening stress, that will typically be applied by field
personnel tightening the bolts. This computed value is printed in the output from
the flange program.
It is interesting to compare this value to the bolt stress printed in the ASME
stress report (also in the output). It is not unusual for the rule-of-thumb
tightening stress to be larger than the ASME required stress. When the ASME
required stress is entered into the Bolt Initial Tightening Stress data field, a
comparison of the leakage safety factors can be made and the sensitivity of the
joint to the tightening torque can be ascertained. Users are strongly encouraged
to play with these numbers to get a feel for the relationship
between all of the factors involved.
Axial Stiffness
Torsional Stiffness
Transverse Stiffness
Bending Stiffness
the hot and the cold loads must be within the spring allowed working
range.
If
the user specified an allowed load variation then the absolute value of the
product of the travel and the spring rate divided by the hot load must be less
than the specified variation.
If
the user specified some minimum available clearance then the spring
selected must fit in this space.
When the reduced branch rules apply, the following equations are used for the
local stiffnesses:
TRANSLATIONAL:
ROTATIONAL:
AXIAL = RIGID
AXIAL = RIGID
CIRCUMFERENTIAL
=
CIRCUMFERENTIAL
=
(kx)d/EI
RIGID
LONGITUDINAL = (kz)d/EI
LONGITUDINAL = RIGID
where:
RIGID = 1.0 E12 lb./in. or 1.0 E12 in.lb./deg.
d
= Branch diameter
E
= Youngs Modulus
I
= Cross Section Moment of Inertia
D
= Header diameter
T
= Header thickness
Tb
= Branch fitting thickness
kx
= 0.1(D/T)1.5[(T/t)(d/D)]0.5(Tb/T)
kz
= 0.2(D/T)[(T/t)(d/D)]0.5(Tb/T)
The following input parameters are required to get a leakage report. These
parameters include:
Flange Inside Diameter
Flange Thickness
Bolt Circle Diameter
Number Of Bolts
Bolt Diameter
Effective Gasket Diameter
Uncompressed Gasket Thickness
Effective Gasket Width
Leak Pressure Ratio
Effective Gasket Modulus
Externally Applied Moment
Externally Applied Force
Pressure
Flange Rating
This is an optional input, but results in some very interesting output. As mentioned
above, it has been a widely used practice in the industry to use the ANSI B16.5 and
API 605 temperature/pressure rating tables as a gauge for leakage. Because these
rating tables are based on allowable stresses, and were not intended for leakage
prediction, the leakage predictions that resulted were a function of the allowable
stress for the flange material, and not the flexibility, i.e. modulus of elasticity of the
flange. To give the user a feel for this old practice, the minimum and maximum
rating table values from ANSI and API were stored and are used to print minimum
and maximum leakage safety factors that would be predicted from this method.
Example output that the user will get upon entering the flange rating is shown as
follows:
EQUIVALENT PRESSURE MODEL Equivalent Pressure (lb./sq.in.) 1639.85
ANSI/API Min Equivalent Pressure Allowed 1080.00
ANSI/API Max Equivalent Pressure Allowed 1815.00
This output shows that leakage, according to this older method, occurred if a carbon
steel flange was used, and leakage did not occur if an alloy flange was used. (Of
course both flanges would have essentially the same flexibility tendency to leak.)
The four modified methods vary in the manner in which the corroded area is
estimated.
These methods are:
.85dLThe corroded area is approximated as 0.85 times the maximum pit
depth times the flaw length.
ExactThe corroded area is determined numerically using the trapezoid
method.
EquivalentThe corroded area is determined by multiplying the average pit
depth by the flaw length. Additionally, an equivalent flaw length (flaw length *
average pit depth / maximum pit depth) is used in the computation of the Folias
factor.
EffectiveThis method also uses a numerical trapezoid summation, however,
various sub lengths of the total flaw length are used to arrive at a worst case
condition.
Note that if the sub length which produces the worst case coincides with the
total length, the Exact and Effective methods yield the same result.
Static analysis cannot be performed until the error checking portion of the piping
pre-processor has been successfully completed. Only after error checking is
completed are the required analysis data files created. Similarly, any subsequent
changes made to the model input are not reflected in the analysis unless error
checking is rerun after those changes have been made. CAESAR II does not allow
an analysis to take place if the input has been changed and not successfully error
checked.
Error Checking can only be done from the input spreadsheet, and is initiated by
executing the Error Check or Batch Run commands from the toolbar or menu.
Error Check saves the input and starts the error checking procedure.
Batch Run causes the program to check the input data, analyze the system, and
present the results without any user interaction. The assumptions
are that the loading cases to be analyzed do not need to change
Users may sort messages in the Message Grid by type, message number or
element/node number by double-clicking the corresponding column header.
Users can also print messages displayed in the Message Grid.
The software will give the user feedback when things are not right in the model.
Three types of messages are possible with Caesar II:
Fatal Error Message - Errors are flagged when there is a problem with the
model due to which analysis cannot continue.
Warning Message - Warnings are flagged whenever there is a problem with a
model, which can be overcome using some assumptions.
Note Message - The third category of alert is the informational note. These
messages simply inform the user of some noteworthy fact related to the model.
An example of a note may be a message informing the user of the number of
hangers to be designed by the software.
The first step in the analysis of an error-checked piping model is the specification
of the static load cases.
After entering the static load case editor, a screen appears which lists all of the
available loads that are defined in the input, the available stress types, and the
current load cases offered for analysis. If the job is entering static analysis for the
first time, CAESAR II presents a list of recommended load cases. If the job has
been run previously, the loads shown are those saved during the last session.
The load case input screen is shown on the next slide.
Hydrodynamic Parameters:
Up to four different hydrodynamic load cases may be specified for any one job.
Several hydrodynamic coefficients are defined on the element spreadsheet.
The inclusion of hydrodynamic coefficients causes the loads WAV1, WAV2,
WAV3, and WAV4 to be available in the load case editor.
In the load case editor, four different wave load profiles can be specified.
Current data and wave data may be specified and included together or
either of them may be omitted so as to exclude the data from the analysis.
CAESAR II supports three current models and six wave models.
The static analysis performed by CAESAR II follows the regular finite element
solution routine. Element stiffnesses are combined to form a global system
stiffness matrix. Each basic load case defines a set of loads for the ends of all
the elements. These elemental load sets are combined into system load vectors.
Using the relationship of force equals stiffness times displacement (F=KX),
the unknown system deflections and rotations can be calculated. The known
deflections however, may change during the analysis as hanger sizing, nonlinear
supports, and friction all affect both the stiffness matrix and load vectors. The
root solution from this equation, the system-wide deflections and rotations, is
used with the elements stiffness to determine the global (X,Y,Z) forces and
moments at the end of each element. These forces and moments are translated
into a local coordinate system for the element from which the code-defined
stresses are calculated. Forces and moments on anchors, restraints, and fixed
displacement points are summed to balance all global forces and moments
entering the node. Algebraic combinations of the basic load cases pick up this
process where appropriate - at the displacement, force & moment, or stress
level.
Once the setup for the solution is complete the calculation of the displacements
and rotations is repeated for each of the basic load cases.
Youngs Modulus
The slope of the linear portion of the stress-strain diagram. For structural steel
this value is
usually 29,000,000 psi (199,948 MPa).
Bending Coefficient
The bending coefficient Cb shall be taken as 1.0 in computing the value
of Fby and Fbz for use in Formula 1.6-1a. Cb shall also be unity when the
bending moment at any point in an un-braced length is larger than the
moment at either end of the same length. Otherwise, Cb shall be
Cb = 1.75 + 1.05(M1/M2) + 0.3(M1/M2)2 but not more than 2.3 where
(M1/M2) is the ratio of the smaller to larger moments at the ends.
Form Factor Qa
The form factor is an allowable axial stress reduction factor equal to the
effective area divided by the actual area. (Consult the latest edition of
the AISC code for the current computation methods for the effective
area.)
Allow Sidesway
The ability of a frame or structure to experience sidesway (joint
translation) affects the computation of several of the coefficients used in
the unity check equations. Additionally, for frames braced against
sidesway, moments at each end of the member are required.
Normally sidesway is allowed (i.e., the box is checked).
below are the code stress equations for the actual and allowable stresses used
by CAESAR II. For the listed codes, the left hand side of the equation defines the
actual stress and the right hand side defines the allowable stress. The CAESAR
II load case label is also listed after the equation.
US Code Stresses
Stress Cat.
Stress Cat.
BS 7159 (contd.)
ELASTIC
MODULUS
(lb/in2)
POISSONS
RATIO
DENSITY
(lb/in3)
29.5 E6
0.2920
0.28993
-325
1400
29.3 E6
0.2890
0.28009
-325
1400
29.2 E6
0.2890
0.28935
-325
1400
29.7 E6
0.2890
0.28935
-325
1400
30.9 E6
0.2890
0.28935
-325
1400
Austenitic Stainless
28.3 E6
0.2920
0.28930
-325
1400
Straight Chromium
29.2 E6
0.3050
0.28010
-325
1400
28.3 E6
0.3050
0.28990
-325
1400
Wrought Iron
29.5 E6
0.3000
0.28070
-325
1400
13.4 E6
0.2110
0.25580
70
1000
26.0 E6
0.3150
0.31870
-325
1400
K-Monel
26.0 E6
0.3150
0.30610
-325
1400
Copper Nickel
22.0 E6
0.3300
0.33850
-325
1400
Aluminum
10.2 E6
0.3300
0.10130
-325
600
Copper 99.8% Cu
16.0 E6
0.3550
0.32270
70
400
Commercial Brass
17.0 E6
0.3310
0.30610
-325
1200
14.0 E6
0.3300
0.31890
-325
1200
MATERIAL NAME
TEMPERATURE
RANGE (F)
PIPING CODE
PUBLICATION DATE
REVISION DATE
ANSI B31.1
2004
16-Aug-04
ANSI B31.3
2004
29-Apr-05
ANSI B31.4
2002
4-Oct-02
2002
4-Oct-02
ANSI B31.5
2001
30-May-05
ANSI B31.8
2003
6-Feb-04
2003
6-Feb-04
ANSI B31.11
2002
30-May-03
2004
1-Jul-05
2004
1-Jul-05
1984
N/A
CANADIAN Z662
(9/95)
N/A
CANADIAN Z662
Ch 11 (9/95)
N/A
BS 806, ISSUE 1
Sept. 1993
N/A
STOCKHOLM, 1979
N/A
STOCKHOLM 1979
N/A
ANSI B31.1
1967
N/A
STOOMWEZEN
1989
N/A
RCC-M C
1988
N/A
RCC-M D
1988
N/A
CODETI
2001
Jun-04
NORWEGIAN
1999
N/A
FDBR
1995
N/A
BS7159
1989
N/A
UKOOA
1994
N/A
IGE/TD/12
2003
N/A
DnV
1996
N/A
EN-13480
(3/2002)
N/A
GPTC/192
1998
N/A
1.
2.
3.
4.
5.