PIPING STRESS

ANALYSIS
BY CAESAR-II SOFTWARE

CAESAR MODELING

ANALYSIS

REPORT

FDC PIPING
 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.

Cont.
FDC PIPING
 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.

FDC PIPING
To avoid excessive piping vibration
WORK FLOW DIAGRAM
FOR STRESS GROUP
 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

Piping Stress Analysis Software

CAESAR II 4.5

In-house software (Tracking system)

SATS
SSTS
CAESAR CONVERT

FDC PIPING
 MODELLING

Piping Components
Piping
Equipments
Restraints

Cont.
FDC PIPING
 NODE SKETCH

Cont.
FDC PIPING
STRESS ISO MARKUP
 CAESAR INPUT
SPREADSHEET
Start Run
Batch Run
Allowable Stress At Cold Condition

Geometry Allowable
Stress At
Caesar Modelling Hot
Material Selection Condition
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

STATIC ANALYSIS

DYNAMIC ANALYSIS

FDC PIPING
 TYPES OF STRESSES

PRIMARY

SECONDARY

FDC PIPING
 TYPES OF LOAD

Sustain Load
Occasional Load
Thermal Load
Hydro Test Load

FDC PIPING
 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

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)

FDC PIPING
CAESAR LOAD CASES

DESIGN TEMP. LOAD CASE

OPERATING TEMP. LOAD CASE

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

Both pump operating.

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

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).
 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 Compliance
FDC 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 sheet
FDC PIPING
 SAQ SHEET
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.
CAESAR DUMP
RESTRAINT OUTPUT
SPRING DATASHEET
User is given an unlocked cell (F53) to write any special comment / note. GO TO

MAINTENANCE

EL 1
(U/S STL.)

CL

EL.2
CL

C
L

EL1-EL2=1500 mm
''B'' TYPE HANGER BOTTOM CONNECTION
SPRING DETAILS File name: BAWB401D Calc No.: Node No.: 1820
LINE NO.: 951-WB401-10"-EC62EM-HC25 TYPE: B SIZE: 16 FIG: VS2
ISO OR GA NO.: F1951-951-WB012A BOTTOM CONNECTION NO.: 6
INSTALLED LOAD: 32.626 KN PIPE SIZE: 10" PIPE MATERIAL: CS
OPERATING LOAD: 32.812 KN EL1.: 49137 EL2.: 47637 EL3.:
o
TEST LOAD: 48.939 KN DESIGN TEMPERATURE: 150 C
TRAVEL (+ UP / - DOWN): -0.560 mm P/SUPP TYPE: NA K 333.2 N/mm
TRAVEL (AXIAL): 1.000 mm TRAVEL (LATERAL): 1.000 mm
MANUFACTURER: SARATHI MATCODE MAINTECE % VARIABILITY 0.6
1. All welds to be 6mm CFW unless otherwise noted.
NOTES: QUANTITY REQUIRED
2. All make-up components to be supplied by the manufacturer.
3. All bottom connection material to be suited with pipe material.
1
4. Elevations (EL) are in mm.

1 13-12-2005 Issued for Construction RVB SS MGC RPL

0 01-09-2003 Issued for Construction RRR SS MGC RPL
DES'N CHKD APPD PROJ.
REV. DATE REVISION CLIENT
ENGR BY BY ENGR
RELIANCE INDUSTRIES LIMITED
JAMNAGAR REFINERY PROJECT FIELD DESIGN CELL
VARIABLE SPRINGS JOB No DRAWING No REV
PIPE SUPPORT STANDARD 22960 951Y-SPR-004 1

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

SPS DRAWING
BELLOW DATASHEET
 LOAD SUMMARY SHEET
Reliance Engineering Associates Private Ltd.

Load Summary Chart

Date of Ge ne ration: 14-Jan-06
File Location: c:\s tre s s out\KB 038A001401141157.xls

Max. Static Max. Composite Occ Sustained Design Operating

Node
Fx Fy Fz Fx Fy Fz Fx Fy Fz Fx Fy Fz Fx Fy Fz
10 -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 556
130 -689 -11710 3445 -647 -13980 3174 299 -3528 322 -689 -11710 3445 -647 -10799 3174
140 -5500 -26565 7648 -5109 -23280 7567 -898 -21080 223 -5500 -20273 7648 -5109 -20428 7567
170 1326 -27275 6542 704 -23156 6541 1035 -21389 -427 742 -21947 6542 704 -21930 6541
210 -4914 -22514 -967 -4895 -18103 -967 -169 -17668 553 -4914 -16628 -861 -4895 -16631 -967
220 -4877 -12546 -6954 -4831 -11815 -28705 -95 -9839 -22 -4877 -9512 -6954 -4831 -9548 -6784
230 -3838 -16219 217 -3833 -13389 217 -54 -12723 4 -3838 -12808 193 -3833 -12798 217
240 9691 -15425 2121 50488 -12233 2005 -31 -12099 -1 9691 -12077 2121 9349 -12079 2005
250 3532 -15003 -4500.9 3531 -11814 -66 -18 -11768 -3530.4 3532 -11774 -60 3531 -11774 -66
260 4123 -17525 -5257.5 4123 -13755 -10608 -11 -13746 -4123.8 4123 -13745 -52 4123 -13745 -56
270 1440 -6118 -1835.4 1440 -4801 -14 -8 -4799 -1439.7 1440 -4799 -14 1440 -4799 -14
580 -6309 -3048 1893 -30719 -2294 1820 -143 -2778 -83 -6309 2 1893 -6087 -210 1820
590 1086 -3479 -323 1048 -3593 -2344 -45 -2643 29 1086 -3479 -323 1048 -3402 -288
600 713 -3097 -8 713 -2467 -1 -15 -2599 -8 707 -2356 -2 713 -2378 -1
610 998 -3515 357 992 -3094 2096 -7 -2908 2 998 -3010 357 992 -3002 350
640 745 -3056 -916.8 745 -2561 -36 1 -2548 -1 743 -2480 -34 745 -2485 -36
650 -1011.3 -3371 -1011.3 952 -2912 -2186 -839.4 -2798 -839.4 958 -2884 -334 952 -2877 -322
660 -959.4 -3198 6 728 -2439 6 1 -2658 -1 721 -2405 5 728 -2426 6
670 1084 -3614 44 1060 -3551 1916 1 -2681 3 1084 -3614 44 1060 -3534 37
680 279 -3285 -16 279 -986 7 4 -2729 -13 222 -742 6 279 -929 7
690 17 -3298 65 0 1230 1740 14 -2791 51 0 0 21 0 0 17
805 662 -12263 3619 4126 -19457 3619 -45 -8552 -192 662 -12263 3619 609 -12232 3619
875 334 -10434 -3757 334 -17659 -8978 52 -7854 164 149 -10434 -3161 334 -10185 -3757
960 2678 -2340 -532 4886 2336 -510 91 -1943 -120 2678 603 -532 2495 548 -510
985 -90 -1900 -563 -70 -2389 -481 -76 -1554 -460 -69 -1599 -475 -70 -1621 -481
990 -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 623
1100 746 -11349 3322 282 -10415 2670 -39 -5361 94 746 -11349 3322 282 -8949 2670
1140 -876 -17708 -5240 -734 -15470 -4307 28 -9575 -179 -876 -17708 -5240 -734 -14562 -4307
1220 -1472 -8969 -800 -1472 -6209 -638 -225 -7491 281 -965 -4179 -800 -1472 -5347 -638
1250 -1786 -7238 1407 -1392 -7528 1407 172 -6088 -65 -1786 -7151 1189 -1392 -6596 1407
1260 -2088 -8217 -1310 -1651 -8135 -1100 -55 -5653 -22 -2088 -8217 -1310 -1651 -8018 -1100
1270 168 -7976 -503 12594 -5832 -503 -38 -6698 22 0 0 0 168 -1641 -503
1299 -954 -12798 -3719 -484 -20930 -3371 130 -8447 -39 -954 -12798 -3719 -484 -11352 -3371
1410 1262 -3049 729 2191 -12199 8028 -100 -2350 -38 1262 -3049 -380 668 -2981 729
1620 1564 -8812 -535 1564 -6172 -256 234 -7358 193 1144 -4211 -535 1564 -5281 -256
1640 1896 -7262 1227 1604 -7446 1227 -168 -6108 -61 1896 -7215 1045 1604 -6733 1227
1650 2137 -8183 -1281 2044 -8373 -1281 56 -5645 -20 2137 -8183 -1209 2044 -8041 -1281
1660 -240 -7980 -493 -12267 -6298 -493 35 -6701 23 0 0 0 -240 -1521 -493
1689 955 -13120 -3818 467 -20978 -3490 -122 -8829 -38 955 -13120 -3818 467 -11736 -3490
1800 -1259 -3067 1001 -1764 -11820 8638 95 -2342 -39 -1259 -3067 89 -651 -3032 1001
3010 1246 -7833 1407 757 -11537 1401 -34 -6972 366 1246 -6263 1407 757 -5308 1401
3070 600 -2164 304 552 -2415 304 -17 -1880 -38 600 -2132 220 552 -2099 304
4050 -2495 -12491 2801 -2490 -14246 2801 -1801.8 -6006 -1802 -2495 -12206 2680 -2490 -12491 2801
4070 -248 -4676 1381 0 1316 0 -167 -3602 1068 0 0 0 0 0 0
4120 -15837 -31157 -2994 -19092 -11612 -2599 711 -23909 -1135 -15837 -4411 -2994 -9860 -8782 -2599
4150 16655 0 21194 18228 0 22805 0 0 0 16655 0 21194 10765 0 13646
4170 4653 -83854 24722 2841 -45483 12902 1619 -27407 -728 4653 -83854 24722 2841 -44038 12902
 COMPLETED STRESS ISO

FDC PIPING
 PRACTICAL SESSION
DEMONSTRATION OF CAESAR
THANK
YOU!!