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

FDC PIPING

Dynamics of flowing fluid.

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.

FDC
PIPING

To avoid excessive piping vibration

WORK FLOW DIAGRAM

FOR STRESS GROUP
Process Dept.

Instrumentation
Dept.

P&ID
LDT

Instrument data

Fabrication
and Erection
Isometric

Piping Team
Supports Loadings
for pipe support
selection, pipe
displacements at
operating temp.

Civil Dept.

SAQ,
alongwith
Stress
Isometrics
and other
data

Site/ Field
Spring, SPS,
Specials data
sheets, Site problem
resolutions, Audit
Reports

Mechanical
Dept.

Stress Analysis
Team
Soil
Characteristics

Civil and
Structural
Support loadings

Equipment
G.A.'s

Stress Analysis
Report

Cleat Loads, Nozzle

loads if more than
allowables

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

Caesar Modelling
Material Selection

Allowable
Stress At
Hot
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

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
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 10-2030-40-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 2030-40-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

FDC PIPING

Displacement

Restraints

Restraints Summary

Global Element Forces

Local Element Forces

Stresses

Sorted Stress

Code Compliance

REPORT INTERPRETATION

FDC PIPING

Hanger Table

Hanger Table W/Text

Input Echo

Miscellaneous Data

Load Case Report

Warnings

OUTPUT SHEET

REPORTING

FDC PIPING

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

SAQ SHEET
Stress Analysis Query Report

Job No. :

22960

Job Title :

Jamnagar Refinary Project -

Complex :

Coke

Description :

Tie-In for
Heater

Package No. :

Coke-371-041-00

Analyst :

rajeshr

Isometrics :

A15-371PA017, A09-

Reason for analysis :

Ref. Doc. :

Unit :

371

Title : QYI/COK

Rev.: 0

Caesar File name : KA041A00

Date of issue : 18/11/2003

Others

Enclosed - Stress Isometrics Caesar Dump -

Attached sheets
Attached

Load Summary Report Caesar front sheet - for ref.

Attached
Attached

Spring Report Spring Datasheets SPS drawing -

Stress Remarks:

Pump/Equipment datasheet/drawing -

Attached

Copy of LDT -

Attached

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

MA INTENA NCE

EL 1
(U/S STL.)

CL

EL.2

CL
C
L
EL1-EL2=1500 mm

''B'' TYPE HANGER

SPRING DETAILS
LINE NO.:

File name:

BA WB401D

951-WB401-10"-EC62EM-HC25
F1951-951-WB012A

ISO OR GA NO.:

BOTTOM CONNECTION
Calc No.:
TYPE:

16

32.626 KN

PIPE SIZE:

OPERATING LOAD:

32.812 KN

EL1.:

TEST LOAD:

48.939 KN

DESIGN TEMPERATURE:

TRAVEL (+ UP / - DOWN):

-0.560 mm

P/SUPP TYPE:

1.000 mm

MANUFACTURER:

SA RA THI

10"

49137 EL2.:

MATCODE

47637 EL3.:
150

NA

TRAVEL (LATERAL):

1.000

MA INTECE

RVB

SS

01-09-2003 Issued for Construction

RRR
DES'N
ENGR

SS
CHKD
BY

RELIANCE
INDUSTRIES
LIMITED
JAMNAGAR REFINERY PROJECT

Remark:

N/mm

mm
0.6

13-12-2005 Issued for Construction

REVISION

C
333.2

% VARIABILITY

DATE

QUANTITY REQUIRED

REV.

VS2

CS

PIPE MATERIAL:

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.

NOTES:

FIG:
6

BOTTOM CONNECTION NO.:

INSTALLED LOAD:

TRAVEL (AXIAL):

1820

Node No.:

B SIZE:

MGC
MGC
APPD PROJ.
BY
ENGR

RPL
RPL
CLIENT

FIELD DESIGN CELL

VARIABLE SPRINGS

JOB No

DRAWING No

REV

PIPE SUPPORT STANDARD

22960

951Y-SPR-004

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:
File Location:

Node
10
120
130
140
170
210
220
230
240
250
260
270
580
590
600
610
640
650
660
670
680
690
805
875
960
985
990
1000
1100
1140
1220
1250
1260
1270
1299
1410
1620
1640
1650
1660
1689
1800
3010
3070
4050
4070
4120
4150
4170

14-Jan-06
c:\s tre s s out\KB038A001401141157.xls

Max. Static
Fx
Fy
Fz
-3026
-283
-689
-5500
1326
-4914
-4877
-3838
9691
3532
4123
1440
-6309
1086
713
998
745
-1011.3
-959.4
1084
279
17
662
334
2678
-90
-1484
1461
746
-876
-1472
-1786
-2088
168
-954
1262
1564
1896
2137
-240
955
-1259
1246
600
-2495
-248
-15837
16655
4653

-15458
-19172
-11710
-26565
-27275
-22514
-12546
-16219
-15425
-15003
-17525
-6118
-3048
-3479
-3097
-3515
-3056
-3371
-3198
-3614
-3285
-3298
-12263
-10434
-2340
-1900
-3195
-3008
-11349
-17708
-8969
-7238
-8217
-7976
-12798
-3049
-8812
-7262
-8183
-7980
-13120
-3067
-7833
-2164
-12491
-4676
-31157
0
-83854

-11511
814
3445
7648
6542
-967
-6954
217
2121
-4500.9
-5257.5
-1835.4
1893
-323
-8
357
-916.8
-1011.3
6
44
-16
65
3619
-3757
-532
-563
-3820
699
3322
-5240
-800
1407
-1310
-503
-3719
729
-535
1227
-1281
-493
-3818
1001
1407
304
2801
1381
-2994
21194
24722

Max. Composite Occ

Fx
Fy
Fz
-11585
-283
-647
-5109
704
-4895
-4831
-3833
50488
3531
4123
1440
-30719
1048
713
992
745
952
728
1060
279
0
4126
334
4886
-70
-1291
4403
282
-734
-1472
-1392
-1651
12594
-484
2191
1564
1604
2044
-12267
467
-1764
757
552
-2490
0
-19092
18228
2841

-12790
-13086
-13980
-23280
-23156
-18103
-11815
-13389
-12233
-11814
-13755
-4801
-2294
-3593
-2467
-3094
-2561
-2912
-2439
-3551
-986
1230
-19457
-17659
2336
-2389
-3833
-2397
-10415
-15470
-6209
-7528
-8135
-5832
-20930
-12199
-6172
-7446
-8373
-6298
-20978
-11820
-11537
-2415
-14246
1316
-11612
0
-45483

-39967
556
3174
7567
6541
-967
-28705
217
2005
-66
-10608
-14
1820
-2344
-1
2096
-36
-2186
6
1916
7
1740
3619
-8978
-510
-481
-14357
623
2670
-4307
-638
1407
-1100
-503
-3371
8028
-256
1227
-1281
-493
-3490
8638
1401
304
2801
0
-2599
22805
12902

Sustained
Fx
Fy
Fz
-147
20
299
-898
1035
-169
-95
-54
-31
-18
-11
-8
-143
-45
-15
-7
1
-839.4
1
1
4
14
-45
52
91
-76
-58
18
-39
28
-225
172
-55
-38
130
-100
234
-168
56
35
-122
95
-34
-17
-1801.8
-167
711
0
1619

-14754
-17646
-3528
-21080
-21389
-17668
-9839
-12723
-12099
-11768
-13746
-4799
-2778
-2643
-2599
-2908
-2548
-2798
-2658
-2681
-2729
-2791
-8552
-7854
-1943
-1554
-2531
-2517
-5361
-9575
-7491
-6088
-5653
-6698
-8447
-2350
-7358
-6108
-5645
-6701
-8829
-2342
-6972
-1880
-6006
-3602
-23909
0
-27407

704
519
322
223
-427
553
-22
4
-1
-3530.4
-4123.8
-1439.7
-83
29
-8
2
-1
-839.4
-1
3
-13
51
-192
164
-120
-460
220
-172
94
-179
281
-65
-22
22
-39
-38
193
-61
-20
23
-38
-39
366
-38
-1802
1068
-1135
0
-728

Fx

Design
Fy
Fz

-3026
-83
-689
-5500
742
-4914
-4877
-3838
9691
3532
4123
1440
-6309
1086
707
998
743
958
721
1084
222
0
662
149
2678
-69
-1484
1461
746
-876
-965
-1786
-2088
0
-954
1262
1144
1896
2137
0
955
-1259
1246
600
-2495
0
-15837
16655
4653

-8704
-635
-11710
-20273
-21947
-16628
-9512
-12808
-12077
-11774
-13745
-4799
2
-3479
-2356
-3010
-2480
-2884
-2405
-3614
-742
0
-12263
-10434
603
-1599
-3195
-925
-11349
-17708
-4179
-7151
-8217
0
-12798
-3049
-4211
-7215
-8183
0
-13120
-3067
-6263
-2132
-12206
0
-4411
0
-83854

-9998
172
3445
7648
6542
-861
-6954
193
2121
-60
-52
-14
1893
-323
-2
357
-34
-334
5
44
6
21
3619
-3161
-532
-475
-3754
699
3322
-5240
-800
1189
-1310
0
-3719
-380
-535
1045
-1209
0
-3818
89
1407
220
2680
0
-2994
21194
24722

Operating
Fx
Fy
Fz
-2474
-283
-647
-5109
704
-4895
-4831
-3833
9349
3531
4123
1440
-6087
1048
713
992
745
952
728
1060
279
0
609
334
2495
-70
-1291
977
282
-734
-1472
-1392
-1651
168
-484
668
1564
1604
2044
-240
467
-651
757
552
-2490
0
-9860
10765
2841

-9314
-2080
-10799
-20428
-21930
-16631
-9548
-12798
-12079
-11774
-13745
-4799
-210
-3402
-2378
-3002
-2485
-2877
-2426
-3534
-929
0
-12232
-10185
548
-1621
-3096
-1178
-8949
-14562
-5347
-6596
-8018
-1641
-11352
-2981
-5281
-6733
-8041
-1521
-11736
-3032
-5308
-2099
-12491
0
-8782
0
-44038

-11511
556
3174
7567
6541
-967
-6784
217
2005
-66
-56
-14
1820
-288
-1
350
-36
-322
6
37
7
17
3619
-3757
-510
-481
-3820
623
2670
-4307
-638
1407
-1100
-503
-3371
729
-256
1227
-1281
-493
-3490
1001
1401
304
2801
0
-2599
13646
12902

COMPLETED STRESS ISO

FDC PIPING

PRACTICAL SESSION
DEMONSTRATION

OF CAESAR

THANK
YOU!!