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Mathematical model
of piping system built
using Caesar II
software.
BUILDING A MODEL WITH CAESAR II
Engineers nowadays do not have to worry about solving
higher degree, or differential equations to perform
complicated calculations, because they can create
complete models of the system they are trying to design
and analyse and let the software perform the analysis
for them. However as the saying goes, “garbage in;
garbage out” the engineer still has to possess good
engineering judgment to know what to expect from a
computer analysis and how to interpret the output.
Although there are various softwares available to do
pipe stress analyses, Caesar II is one that is well known
and frequently used for the oil and gas engineering
analyses.
USING CAESAR II FOR PIPE ANALYSIS
CAESAR II is most often used for the mechanical design of new piping systems. Hot piping
systems present a unique problem to the mechanical engineer—these 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 piping-related equipment (API, NEMA, or Expansion Joint
Manufacturers’ Association - EJMA).
CAESAR II is not limited to thermal analysis of piping systems. CAESAR II also has the
capability of modeling and analyzing the full range of static and dynamic loads, which may
be imposed on the system. Therefore, CAESAR II is not only a tool for new design but it is
also valuable in troubleshooting or re-designing existing systems. Here, one can determine
the cause of failure or evaluate the severity of un-anticipated operating conditions such as
fluid/piping interaction or mechanical vibration caused by rotating equipment.
CONFIGURING CAESAR II
Each time CAESAR II starts, the configuration file caesar.cfg is read from the
current data directory. If this file is not found in the current data directory,
eventually a fatal error will be generated and CAESAR II will terminate.
To generate the caesar.cfg file select Tools/Configure/Setup (or the Configure
button from the toolbar) from the CAESAR II Main Menu.
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.
CAESAR II – COMPUTATIONAL CONTROL
Use Pressure Stiffening on Bends- if used it will be the maximum of all psi
CONTROL CONFIGURATION SETTINGS Missing Mass ZPA- defaults to the last “extracted” mode
Bend Axial Shape- if ignored the bend will be stiffer
Rod Tolerance (degrees)- The default of CAESAR II is 1.0 degree
Rod Increment (Degrees)- for difficult-to-converge problems, use 0.1
Alpha Tolerance- the default value is 0.05
CAESAR II – COMPUTATIONAL
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:
OD—Hoop stress is computed according to Pd/2t where “d” is the outer diameter
of the pipe.
Mean—Hoop stress is computed according to Pd/2t where “d” is the average or
mean diameter of the pipe.
Lamés—Hoop stress is computed according to Lamés equation, = P ( Ri2 + Ri2 *
Ro2 / R2 ) / ( Ro2 - Ri2 ) and varies through the wall as a function of R
CONTROL CONFIGURATION SETTINGS
No RFT/WLT in Reduced Fitting SIFs- If enabled will use distinct in-plane and
out-of-plane SIFs
Implement B31.3 Appendix P- implements the alternate rules in B31.3
Appendix P.
Bends:
Stiffened Bends Restraints:
90-degree Bends Anchors
IMPORTANT TOPICS IN MODEL
The minimum and maximum total bend angle is specified by the Minimum
Bend Angle and Maximum Bend Angle parameters in the Configure Setup—
Geometry section.
MODELLING PIPE BENDS (CONT’D.)
MODELLING PIPE SINGLE AND DOUBLE-FLANGED
BENDS
Single and double flanged bend specifications only affect the stress
intensification and flexibility of the bend. There is no automatic rigid element
(or change in weight) generated for the end of the bend.
Single and double-flanged bends are indicated by entering 1 or 2
(respectively) for the Type in the bend auxiliary input.
Rigid elements defined before or after the bend will not alter the bend's
stiffness or stress intensification factors.
When specifying single flanged bends it does not matter which end of the
bend the flange is on.
If the user wishes to include the weight of the rigid flange(s) at the bend
ends, then he/she should put rigid elements (whose total length is the length
of a flange pair) at the bend ends where the flange pairs exist.
As a guideline, British Standard 806 recommends stiffening the bends
whenever a component that significantly stiffens the pipe cross section is
found within two diameters of either bend end.
MODELLING PIPE
SINGLE AND
DOUBLE-
FLANGED BENDS
MODELLING PIPE 180º RETURN BENDS
Two 90-degree bends
should be separated by
twice the bend radius.
The far-point of the first
bend is the same as the
near-point of the second
(following) the bend.
Where:
Req - equivalent miter bend radius
S - spacing of the miter cuts along the centerline
Ɵ - code defined half-angle between adjacent miter cuts: Ɵ = α / 2N
And where:
α - total bend angle
N - number of cuts
MODELLING PIPE CLOSELY-SPACED MITER BENDS
An additional parameter ‘B’ (length of miter segment at crotch) is checked for
closely spaced miters when using B31.1. ‘B’ may be found for evenly spaced
miters from equation:
B = S [ 1 - ro / Req ]
Where:
ro - outside radius of pipe cross-section
Miter bends are closely spaced if:
S < r [ 1 + tan (Ɵ) ]
Where:
S - miter spacing
r - average pipe cross section radius: (ri+ro)/2
Ɵ - one-half the angle between adjacent miter cuts.
ASME B31.1 has the additional requirements that:
B > 6 tn
Ɵ ≤ 22.5 deg.
B - length of the miter segment at the crotch.
tn - nominal wall thickness of pipe.
MODELLING PIPE CLOSELY-SPACED MITER BENDS
Closely spaced miters regardless of the number of miter cuts may be entered as
a single bend. CAESAR II will always calculate the spacing from the bend radius.
If the user has the miter spacing and not the bend radius, the radius must be
calculated as shown below.
The mitered bend shown 2 slides above has 4 cuts through 90 degrees and a
spacing of 15.913 inches.
Ɵ ≤ 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 (Ɵ)] / 2
R - reduced bend radius for widely spaced miters.
During error checking, CAESAR II will produce a warning message for each
mitered component, which does not pass the test for a closely spaced miter.
These components should be re-entered as a group of single cut joints.
MODELLING PIPE WIDELY-SPACED MITER BENDS
Pipe O. D. = 10.375 in Calculate the Δ coordinates to get from the
Pipe Thk. = 0.500 in tangent intersecting point of the single cut
Bend Angle = 90 degrees miter bend at node 10 to the single cut
Cuts = 2 miter bend at node 15.
Req = 45 in
Note: The straight pipe section coming into and going out of the bend
must be ≥ Req sin (Ɵ).
MODELLING ELBOWS WITH DIFFERENT WALL
THICKNESSES
When the fitting thickness in the bend auxiliary field is entered, CAESAR II
changes the thickness of the curved portion of the bend element only. The
thickness of any preceding or following straight pipe is unaffected.
The specified fitting thickness applies for the current elbow only and is not
carried on to any subsequent elbows in the job.
Stresses at the elbow are calculated based on the section modulus of the
matching pipe as specified in the B31 codes.
However, stress intensification factors and flexibility factors for the bend are
based on the elbow wall thickness.
The elbow at node 10 (in the next slide) has a thickness larger than the
matching pipe wall. The matching pipe has a thickness of 0.5
MODELLING ELBOWS WITH DIFFERENT WALL
THICKNESSES (CONT’D.)
RESTRAINTS
Anchors; Connecting nodes can be used with anchors to rigidly fix one point in
the piping system to any other point in the piping system.
Double-acting restraints; Double-acting restraints are those that act in both
directions along the line of action. Most commonly used restraints are double-
acting. A CNode is the connecting node.
Single-directional restraints; Friction and gaps may be specified with single-
directional restraints. A CNode is the connecting node.
Guides; Guides are double-acting restraints with or without a specified gap.
Connecting Nodes (CNodes) can be used with guides.
Limit Stop; Limit stops are single- or double-acting restraint whose line of action
is along the axis of the pipe. These can have gaps too. A gap is a length, and is
always positive.
Windows; Equal leg windows are modeled using two double-acting restraints
with gaps orthogonal to the pipe axis. Unequal leg windows are modeled using
four single-acting restraints with gaps orthogonal to the pipe axis.
RESTRAINTS (CONT’D.)
Vertical / Horizontal Dummy Legs; Dummy legs and/or any other elements
attached to the bend curvature should be coded to the bend tangent
intersection point. For each dummy leg/bend model a warning message is
generated during error checking in CAESAR II.
Large Rotation rods; Large rotation rods are used to model relatively short rods,
where large orthogonal movement of the pipe causes shortening of the restraint
along the original line of action. These can be entered in any direction. Large
rotation is generally considered to become significant when the angle of swing
becomes greater than 5 degrees.
Static Snubbers; Translational restraints that provide resistance to displacement
in static analysis of occasional loads only. Static snubbers may be directional,
(i.e. may be preceded by a plus or minus sign).
Plastic Hinges; Two bi-linear supports are used to model rigid resistance to
bending until a breakaway force (yield force) is exceeded at which point bending
is essentially free.
Sway Brace assemblies; The sway brace is composed of a single compression
spring enclosed between two movable plates. Manufacturers typically
recommend a specific size sway brace for a given pipe nominal diameter.
SPRING HANGERS
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.
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.
NOTES ON BOLT TIGHTENING STRESS
This is a critical item for leakage determination and for computing
stresses in the flange.
The ASME code bases its stress calculations on a pre-specified, fixed equation
for the bolt stress. The resulting value is however often not related to the actual
tightening stress that appears in the flange when the bolts are tightened. For
this reason, the initial bolt stress input field that appears in the first section of
data input, Bolt Initial Tightening Stress, is used only for the flexibility/leakage
determination. The value for the bolt tightening stress used in the ASME flange
stress calculations is as defined by the ASME code:
Bolt Load = Hydrostatic End Force + Force for Leak-tight Joint
If the Bolt Initial Tightening Stress field is left blank, CAESAR II uses the value:
45000 / √(dbolt)
where 45,000 psi is a constant and d is the nominal diameter of the bolt
(correction is made for metric units).
NOTES ON BOLT TIGHTENING STRESS (CONT’D.)
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.
MODELLING EXPANSION JOINTS
To define an expansion joint, activate the Expansion Joint check box (see
"Expansion Joints" on page 3-21 of the Caesar II manual) on the pipe element
spreadsheet.
The expansion joint will have a non-zero length if at least one of the element’s
spreadsheet Delta fields is non-blank and non-zero. This will usually result in a
more accurate stiffness model in what is typically a very sensitive area of the
piping system.
Four stiffnesses define the expansion joint:
Axial Stiffness
Transverse Stiffness
Bending Stiffness
Torsional Stiffness
These stiffnesses are defined as shown in the figure shown in the next slide:
MODELLING EXPANSION JOINTS (CONT’D.)
Where,
π = 3.14159
Re = Expansion joint effective radius
t = Bellows thickness
E = Elastic Modulus
ν = Poisson’s Ratio
L = Flexible bellows length
CAESAR II will calculate pressure thrust on the expansion joint if the
bellows effective I.D. is given in the expansion joint auxiliary screen.
The mathematical model for pressure thrust applies a force equal to
the pressure times the effective area of the bellows at either end of
the expansion joint. The force will tend to open the bellows if the
pressure is positive, and close the bellows if the pressure is negative.
MODELLING EXPANSION JOINTS (CONT’D.)
According to EJMA (Expansion Joint Manufacturers Association), the
maximum permitted amount of axial movement per corrugation is
defined as erated where,
ex + ey + eq < erated
After the hanger algorithm has run the load cases it needs to size the
hangers. The newly selected springs are inserted into the piping system
and included in the analysis of all remaining load cases.
The spring rate becomes part of the global stiffness matrix, and is
therefore added into all subsequent load cases.
MODELLING PIPE BRANCH FLEXIBILITIES
TRANSLATIONAL: ROTATIONAL:
“The significance of “k” depends upon the specifics of the piping system.
Qualitatively, if “k” is small compared to the length of the piping system,
including the effect of elbows and their k-factors, then the inclusion of “k” for
branch connections will have only minor effects on the calculated moments.
Conversely, if “k” is large compared to the piping system length, then the
inclusion of “k” for branch connections will have major effects. The largest
effect will be to greatly reduce the magnitude of the calculated moments
acting on the branch connection. To illustrate the potential significance of
“k’s” for branch connections, we use the equation [above] to calculate “k”
for a branch connection with D=30 in., d=12.75 in. T=t=0.375 in.:
This compares to the more typical rigid-joint interpretation that k=1, rather
than k=46.6 !”
MODELLING PIPE FLANGES
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
MODELLING PIPE FLANGES (CONT’D.)
Leak Pressure Ratio
This value is taken directly from Table 2-5.1 in the ASME Section VIII code.
This table is reproduced in the help screens of the software. This value is
more commonly recognized as “m”, and is termed the “Gasket Factor” in the
ASME code. This is a very important number for leakage determination, as it
represents the ratio of the pressure required to prevent leakage over the line
pressure.
Young’s 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).
Report Options:
Displacements
Restraints
Restraint summary
Global element forces
Local element forces
Stresses
Stress summary
Code compliance report
Cumulative usage report
To enter the dynamics input, the proper job name must be current prior
to selecting the Analysis-Dynamics file options of the Main Menu.
CODE – STRESS EQUATIONS
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.
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
International Code Stresses Stress Cat.
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
BS 7159 (cont’d.)
CODE – STRESS
EQUATIONS
(CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
CODE – STRESS EQUATIONS (CONT’D.)
AVAILABLE MATERIALS (CAESAR II)
ELASTIC
MATERIAL NAME MODULUS POISSON’S DENSITY TEMPERATURE RANGE (F)
(lb/in2) RATIO (lb/in3)
Low Carbon Steel 29.5 E6 0.2920 0.28993 -325 1400
ANSI B31.5
2002
2001
4-Oct-02
2003
6-Feb-04
6-Feb-04 STANDARDS
ANSI B31.11
2004
30-May-03
1-Jul-05 AVAILABLE IN
ASME SECT III CLASS 3
1984
1-Jul-05
CANADIAN Z662
(9/95)
Ch 11 (9/95)
N/A
N/A CODE-CHECKING A
BS 806, ISSUE 1
STOCKHOLM, 1979
N/A