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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 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.
Use Pressure Stiffening on Bends- if used it will be the maximum of all psi 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 Ambient Temperature- use the ambient temperature Friction Stiffness- default value is 1.0E6 lb./in (non-sliding) Friction Normal Force Variation- default value is 0.15, (15%) Friction Angle Variation- the default is 15 degrees Friction Slide Multiplier- should never be adjusted by the user Coefficient of Friction (Mu)- user defined (0 = no friction) WRC-107 Version / WRC-107 Interpolation Method- the default is to use the last value in the particular WRC table In-core Numerical Check- user enabled Decomposition Singularity Tolerance- the default value is 1.0 E10. Minimum Wall Mill Tolerance (%)- default value is 12.5, (12.5%) Bourdon Pressure- user choice except for FRP pipe; always considered Include / Ignore Spring Hanger Stiffness- user enabled Hanger Default Restraint Stiffness- default value is (1.0 E12 lb/in) Default Translational Restraint Stiffness- default value is (1.0 E12 lb/in) Default Rotational Restraint Stiffness- default value is (1.0 E12 in-lb/deg)
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, ASME-NC(Class 2), ASME-ND(Class 3), NAVY505, Z662, Z662 Chapter 11, BS806, SWEDISH1, SWEDISH2, B31.1-1967, STOOMWEZEN, RCCM-C, 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
B31.3 Sustained SIF Multiplier - the default is 1.0 B31.3 Welding and Contour Tees Meet B16.9- 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. Allow User's SIF at Bend- the default is off Use WRC 329- this activates the WRC329 guidelines for all intersections Use Schneider- activates the Schneider reduced intersection assumptions All Cases Corroded- if enabled, uses the corroded section modulus Liberal Expansion Stress Allowable- user choice to make it default Press. Variation in Expansion Case- user controlled Base Hoop Stress On ( ID/OD/Mean/Lams )- The default is to use the ID of the pipe. If enabled, hoop stress value has the following options:
IDHoop stress is computed according to Pd/2t where d is the internal diameter of the pipe. ODHoop stress is computed according to Pd/2t where d is the outer diameter of the pipe. MeanHoop stress is computed according to Pd/2t where d is the average or mean diameter of the pipe. LamsHoop stress is computed according to Lams equation, = P ( Ri2 + Ri2 * Ro2 / R2 ) / ( Ro2 - Ri2 ) and varies through the wall as a function of R
Use PD/4t- The more comprehensive calculation, i.e. the Default, is recommended Add F/A in Stresses- setting this to Default causes CAESAR II to use whatever the currently active piping code recommends. Add Torsion in SL Stress- setting to Yes will include the torsion term in those codes that dont include it already by default Reduced Intersection- options are B31.1(Pre 1980), B31.1(Post 1980), WRC329, ASME SEC III, and Schneider Class 1 Branch Flexibility- Activates the Class 1 flexibility calculations B31.1 Reduced Z Fix- if used in conjunction with B31.1, it makes the correction to the reduced branch stress calculation that existed in the 1980 through 1989 versions of B31.1 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:
Restraints:
Anchors Guides Limit Stops Windows Double-Acting Restraints
Expansion Joints
Simple Bellows with Pressure Thrust Tied Bellows Universal Joints Hinged Joints Slip Joints Gimbal Joints Ball Joints
Hangers:
Single Can
Liftoff Spring Can Bottom-out Spring Can Constant Effort Hangers
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. Specifying a bend automatically generates two additional intermediate nodes, at the 0-degree location and at the bend midpoint (M). For stress and displacement output the TO node of the element entering the bend is located geometrically at the far-point on the bend. The far-point is at the weld line of the bend, and adjacent to the straight element leaving the bend. 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.
Nodes on the bend curvature cannot be placed closer together than specified by the Minimum Angle to Adjacent Bend parameter in the Configure-SetupGeometry section. This includes the spacing between the nodes on the bend curvature and the near and far-points of the bend. Entering the letter M as the angle designates the bend midpoints. The minimum and maximum total bend angle is specified by the Minimum Bend Angle and Maximum Bend Angle parameters in the Configure SetupGeometry section.
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.
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.
The user is recommended to put nodes at the mid point of each bend comprising the 180 degree return. (See the example on this page)
Evenly spaced mitered bends, whether closely or widely spaced, are uniquely defined by two parameters: Number of cuts (changes in direction) Equivalent radius, or miter spacing. For closely spaced miters the equivalent radius is equal to the code defined R1 for B31.3 and R for B31.1. The equation relating the equivalent radius to the spacing for evenly spaced miters is:
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
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 () ]
Where: S - miter spacing r - average pipe cross section radius: (ri+ro)/2 - one-half the angle between adjacent miter cuts. ASME B31.1 has the additional requirements that: B > 6 tn 22.5 deg. B - length of the miter segment at the crotch. tn - nominal wall thickness of pipe.
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.
Req = S / [ 2 tan () ] = / 2N = 90 / [2(4)] = 11.25 deg. Req = 15.913 / [2 tan (11.25 deg.)] = 40
Note: The straight pipe section coming into and going out of the bend must be Req sin ().
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
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 (CONTD.)
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. Theoretical Cold Load = Hot Load + Travel * Spring Rate where upward travel is positive.
45000 / (dbolt)
where 45,000 psi is a constant and d is the nominal diameter of the bolt (correction is made for metric units).
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 elements 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:
Axial Stiffness
Transverse Stiffness
Torsional Stiffness
Bending Stiffness
Where, = 3.14159 Re = Expansion joint effective radius t = Bellows thickness E = Elastic Modulus = Poissons 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.
The expansion joint rating module can be entered by selecting Main Menu Analysis - Expansion Joint Rating option.
Both 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.
If a single spring cannot be found that satisfies the design requirements, CAESAR II will try to find two identical springs that do satisfy the requirements. If satisfactory springs cannot be found, CAESAR II recommends a constant effort support for the location.
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.
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)
Effective Gasket Modulus Typical values are between 300,000 and 400,000 psi (20,684.27 and 27,579.03 bar) for spiral wound gaskets. The higher the modulus the greater the tendency for the program to predict leakage. Errors on the high side when estimating this value will lead to a more conservative design.
The B31G criteria provides a methodology whereby corroded pipelines can be evaluated to determine when specific pipe segments must be replaced. The original B31G document incorporates a healthy dose of conservatism and as a result, additional work has been performed to modify the original criteria. This additional work can be found in project report PR-3805, by Battelle, Inc. The details of the original B31G criteria as well as the modified methods are discussed in detail in this report.
CAESAR II determines the following values according to the original B31G criteria and four modified methods. These values are:
The hoop stress to cause failure The maximum allowed operating pressure The maximum allowed flaw length
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.
A fatal error would be if no length were defined for a piping element, for example.
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.
(CONTD.)
The user can define up to ninety-nine load cases. Load cases may be edited by clicking on a line in the Load List area.
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).
US Code Stresses
Stress Cat.
BS 7159 (contd.)
ANSI B31.3
ANSI B31.4 ANSI B31.4 Chapter IX ANSI B31.5 ANSI B31.8 ANSI B31.8 Chapter VIII ANSI B31.11
2004
2002 2002 2001 2003 2003 2002
29-Apr-05
4-Oct-02 4-Oct-02 30-May-05 6-Feb-04 6-Feb-04 30-May-03
2004
2004 1984 (9/95) Ch 11 (9/95) Sept. 1993 STOCKHOLM, 1979 STOCKHOLM 1979 1967 1989 1988 1988 2001 1999 1995 1989 1994 2003 1996 (3/2002) 1998
1-Jul-05
1-Jul-05 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A Jun-04 N/A N/A N/A N/A N/A N/A N/A N/A
REFERENCES
1.
2. 3.
4.
COADE, Version 5.00 CAESAR II Applications Guide Caesar II Pipe Analysis software, www.coade.com (Email at techsupport@coade.com) British Standard, BS 806, Pipe Bends Water Resources Council (WRC) Specification 329 Caesar II enhancements and reference topics, http://www.intergraph.com/products/ppm/
END OF PRESENTATION