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CAESAR II Training Original
CAESAR II Training Original
Contents
Introduction ..................................................................................................................... 6
Interface .............................................................................................................................................. 6
Default Data Directory .................................................................................................................... 6
Units .................................................................................................................................................... 7
Create Custom Units File................................................................................................................. 7
F = Kx Example .................................................................................................................................... 9
Model Input .................................................................................................................................. 12
Load Case Editor............................................................................................................................ 16
Hand Calculation ........................................................................................................................... 18
Output Processor .......................................................................................................................... 19
Axial ............................................................................................................................................... 21
Pipe 1 ............................................................................................................................. 42
Input Model ...................................................................................................................................... 43
Error Checking ................................................................................................................................... 52
Review Load Cases ............................................................................................................................ 54
Review Results .................................................................................................................................. 55
Supt 01 ........................................................................................................................... 64
Locating Supports ............................................................................................................................. 65
Adding Supports to Model ............................................................................................................ 69
Analyse .............................................................................................................................................. 75
Fix Model........................................................................................................................................... 80
Place Spring Hangers..................................................................................................................... 87
Turbo ............................................................................................................................. 92
Model Inlet ........................................................................................................................................ 93
Combine Models ............................................................................................................................... 98
NEMA SM23 .................................................................................................................................... 100
Introduction
CAESAR II is pipe stress analysis software which uses beam theory to evaluate piping systems to
numerous international standards. CAESAR II is not Finite Element Analysis (FEA) software, but
instead uses a stick model built up of elements connected by nodes.
This course will introduce CAESAR II and demonstrate various modelling and analysis methods in
order to evaluate and correct piping systems.
Interface
When starting CAESAR II, the Main Window appears. This is the window where all tasks are started
from. This includes opening/creating an input file, reviewing Load Cases, reviewing results or
accessing any auxiliary modules such as WRC 107/297 processor or the ISOGEN stress isometrics
module. All modules open up in their own separate window.
When opening a new file, the file will open, but you will return to the Main Window. You can then
choose to go to the Input processor, Output processor or the results for this file.
These modules (and other auxiliary modules) and their interfaces will be introduced as they occur
throughout the training.
Default Data Directory
CAESAR II has the option to specify the default working directory that is all files working with will
be saved/opened from this default location. Of course it is still possible to navigate using windows
explorer functions, this setting is just the default location when selecting New/Open.
Select File > Set Default Data Directory from the CAESAR II Main window
Click on the ellipsis button at the end of the text field and browse to E:\Training\CAESAR II\Exercises
Units
CAESAR II performs all internal calculations in English units. To enable the entry and review of data in
alternative units (such as SI), units files are used by CAESAR II. These units files simply convert the
internal CAESAR II English units to the users preferred unit. Each CAESAR II file (referred to as a Job
File) uses a particular units file which is specified on creation of the job. Files can be converted
from one units file to another if required. The units files have the extension *.FIL and are located in
the CAESAR II System directory, or in the same directory as the job file. The file to use is specified in
the Configuration file.
Create Custom Units File
Throughout this course, we wish to use specific units for various parameters such as Pressure,
Density etc. As such we require a units file which is different to the supplied default files. So we will
create our own CAESAR II units file.
Select Tool > Make Units Files from the Main Window
This allows the creation of new units files, or the review of existing units files, useful if you receive a
units file from a colleague and wish to check the units in use in the file.
Choose to Create New Units File and for the template file to use as a start point, select *MM.FIL.
Give the new file a name and click View/Edit file.
In the Units File dialogue box, change the following units from the MM defaults:
Stress
Pressure
Elastic Modulus
Pipe Density
Insul. Density
Fluid density
Transl. Stiffness
Uniform Load
N/sq.mm.
bars
N/sq.mm.
kg/cu.m.
kg/cu.m.
kg/cu.m.
N/mm
N/mm
Ensure Nominals is set to ON. This allows the entry of pipe nominal sizes and schedules into the
input, which will be converted to actual diameters and wall thicknesses (e.g. enter 4 into the
diameter field and CAESAR II will convert this to 114.3mm).
Give the file a label as well to easily identify the file.
F = Kx Example
As CAESAR II uses a stick model, and beam theory, it is easy to prove this using a simple cantilever
example. This example will introduce the basic modelling methods in CAESAR II and introduce the
Input Spread Sheet, Load Case editor and the Output Processor. In addition, we can check the
CAESAR II results against some simple hand calculations.
CAESAR II calculates forces using
. Using the example below, we will create a simple
cantilever model, fixed at one end, and apply a displacement of 2mm at the other end. We can then
calculate the force required to generate this 2mm displacement and see this in the results.
After creating the new job file, the first time it has opened, the units will be displayed to the user for
confirmation. You will notice that the units file displayed here for our file is English (CAESAR II
default units) not the units file we have just created. By default, CAESAR II uses the units file set in
the Configuration/Setup as the default file for new jobs (and also as the units to use to display the
output results).
Click OK on the units review screen and the input spread sheet will open. To confirm/check the
units, hover over any field in the input the units used in this field will be displayed in the tooltips.
For example, we changed the pressure units to bars, but the pressure field displays the units as
lb./sq.in.
Close the input screen we will change the units and return to the input with the correct units
displayed.
In the CAESAR II main window select Tools > Configure/Setup
In the window which appears, select Database Definitions from the categories tree on the left.
Now change the Units File Name setting to the units file just created.
10
Return to the Piping Input. Again, the units file to be used will be displayed this should now be
your custom units file.
Verify that the correct units are in use via the tooltips
11
The input spread sheet will have defaulted to nodes 10 to 20, so simply enter 10000 in the DX field.
We are in mm units already.
Enter the pipe diameter and wall thickness this is 8 NS and STD wall thickness. As we have
nominals set to ON, simply type in 8 in the diameter and hit enter. The actual OD for 8 pipe will
be inserted. Repeat for the wall thickness, simply type in S and press enter.
Now we must fill in the pipe properties. We need to know the material properties to carry out the
analysis. Select A106 B from the list of materials. Notice that all materials have a number to
identify it, you can simply type in the material number here - in the case of A106-B this is 106.
Selecting the material will fill in the Elastic modulus and Poisson ratio and various material
allowables under the Allowable Stress area, depending on the design code selected (B31.3 default).
12
That is our pipe itself. We now need to anchor it at one end (node 10) and apply a displacement at
the other end (node 20).
Place the anchor by double clicking the Restraints check box. All the check boxes shown in the
middle column on the spread sheet must be double clicked to check/uncheck.
To define a restraint you must specify a minimum of the node that the restraint will be attached to,
plus the type of restraint. Press F1 for more information on the different restraint types. We need
an anchor, so select ANC and locate it at node 10.
Now we will apply the 2mm displacement at the opposite end. Double click the Displacements
check box to apply a displacement.
13
Finally to complete the analysis we must specify a design temperature and pressure. In our case
these are not really relevant as we are only concerned with displacement, so just enter 21C in T1
and 1bar in P1 fields.
You should see only one note in the error checker report the C of G. This can be useful for
identifying problems such as incorrect densities applied giving an incorrect weight for example.
14
If you receive anything other than this C of G, review the model for any issues. A common error on
this exercise is the following:
This indicates that the displacement and the anchor have been specified at the same location. Check
that the Anchor is specified at Node 10 and the displacement is specified at Node 20.
15
The default load cases are the Operating, Sustained and Expansion cases, as required by the design
codes such as B31.3. Remove all these load cases, as we are only concerned with the displacement.
Into the load case we can add any of the loads defined in the input into the load case. As we are
only concerned with the displacement, drag in D1 Displacement Case #1 into the L1 row.
16
The analysis will now take into account only the displacement reaction.
Before we analyse the piping system, let us first perform the hand calculation in order to check.
17
The stiffness K is
18
You will see the following message explaining that certain loads have been defined in the model but
are not included in any of the load cases to be analysed this is OK in our case, but can serve as a
useful warning if you have may loads/load cases defined. Select OK as isContinue and click OK to
analyse.
Once the analysis is complete, the Output Processor will be shown. We can view various results for
any load case from here, plus general model reports such as the Input Echo. These reports can be
viewed on screen, or output to Word/Excel/Text or straight to a printer.
In addition Custom report templates can be created, and any available report can be selected and
added to the Output viewer Wizard, and exported/viewed to create/view a comprehensive report
very quickly.
For now we will just check the displacement at node 20 to verify that it is 2mm, and the force at
node 20 to check against out hand calculation.
Select the load case (SUS) D1 and the Displacements standard report and click to show on screen:
19
Now to check the force at node 20; view the Global Element Forces report.
37 N as we calculated.
20
The analysis can be quickly re-run in cases where a change such as this has been made by using the
Batch Run Double Running Man icon. This will run the error checker followed immediately by the
analysis (providing there are no Errors).
Therefore:
110,021 N/mm
So for an axial extension of 2mm, the force required is
21
The CAESAR II results, Global Element forces report should verify this:
22
rearranges to
is the section modulus Z. So this reduces further to
The stresses are calculated using this basic theory and compared to the allowable stresses in the
design codes. CAESAR II has many design codes available, all of which have evolved separately over
time, thus the way the stresses are calculated for each specific code are slightly different. However,
looking at one of the most common piping codes B31.3 it can be seen that the equations used
are based on the basic bending as detailed above.
B31.3 Chemical Plant and Petroleum Refinery Piping
Sustained:
Expansion:
23
Sustained Stress: This is primary stresses caused by primary loadings such as the weight and
pressure of the piping system.
Expansion Stress: Expansion stresses are secondary stresses caused by secondary loadings such as
the thermal expansion and applied displacements.
Occasional Stress: Combines sustained stresses with those produced by an occasional loading such
as earthquake of relief valve operation. As these are occasional loads, the allowable can be
increased by a scalability factor, k. k is usually dependant of the duration or frequency of the
occasional load.
24
Where:
Longitudinal Stress
Internal axial force acting on cross section
Cross sectional area of pipe
(
)
Outer diameter
Inner diameter
25
Design pressure
Internal area of pipe
Replacing the terms for the internal and metal areas of the pipe, the previous equation may be
written as
Or:
Bending Stress: Another component of axial normal stress is bending stress. Bending stress is zero
at the neutral axis of the pipe and varies linearly across the cross-section from the maximum
compressive outer fibre to the maximum tensile outer fibre. Calculating the stress as linearly
proportional to the distance from the neutral axis:
Where:
Bending moment acting on cross section
Distance of point of interest from neutral axis of cross section
Moment of inertial of cross section
26
Where:
Outer radius of pipe.
Section modulus of pipe
Summing all components of longitudinal normal stress (for axial and bending):
Hoop Stress: Hoop stress is another of the normal stresses present in the pipe and is caused by
internal pressure. This stress acts in a direction parallel to the pipe circumference.
The magnitude of the hoop stress varies through the pipe wall and can be calculated by Lames
equation as:
(
Where:
Hoop stress due to pressure
Inner radius of pipe
Outer Radius of pipe
Radial position where stress is being considered
The hoop stress can be approximated conservatively for thin-wall cylinders by assuming that the
pressure force applied over an arbitrary length of pipe, l is resisted uniformly by the pipe wall over
that same arbitrary length.
27
Or conservatively
Radial Stress: Radial Stress is the third normal stress present in the pipe wall. It acts in the third
orthogonal direction parallel to the pipe radius. Radial stress is caused by internal pressure and
varies between a stress equal to the internal pressure at the pipes inner surface, and a stress equal
the atmospheric pressure at the pipes external surface. Assuming that there is no external
pressure, radial stress is calculated as:
Where
Radial stress due to pressure
Note that radial stress is zero at the outer radius of the pipe, where the bending stresses are
maximised. For this reason, this stress component has traditionally been ignored during the stress
calculations.
Shear Stresses: Shear Stresses are applied in a direction parallel to the face of the plane of the
crystal structure of the material and tend to cause adjacent planes of the crystal to slip against each
other. Shear stresses may be caused by more than one type of applied load. For example, shear
stress may be caused by shear forces acting on the cross section.
28
Where:
Maximum shear stress
shear force
shear form factor. Dimensionless quantity (1.333 for solid circular section)
These shear stresses are distributed such that they are at the maximum at the neutral axis of the
pipe and zero at the maximum distance from the neutral axis. Since this is the opposite of the case
with bending stresses and since these Shear stresses are usually small, shear stresses due to forces
are traditionally neglected during pipe stress analysis.
Shear Stresses may also be caused by torsional loads.
Where:
Internal torsional moment acting on cross-section
distance of point of interest from torsional centre (intersection of neutral axes) or cross section
torsional resistance of cross section
Maximum torsional stress occurs where c is maximised. Again at the outer radius.
Summing the individual components of the shear stress, the maximum shear stress acting on the
pipe cross section is:
29
Moment of Inertia
Section Modulus
30
Stresses
Longitudinal Stress
Shear Stress
Hoop Stress
Bending Component of
Longitudinal stress
is the radius where the stress is being considered. This will be at a
maximum value at the outer surface where
31
32
There are an infinite number of orientations in which this cube could have been selected, each with
a different combination of normal and shear stresses on the faces. For example, there is one
orientation of the orthogonal stress axes for which one normal stress is maximised and another for
which one normal stress is minimised in both cases; all shear stress components are zero. In
orientation in which the shear stress is zero, the resulting normal components of the stress are
termed the principal stresses. For 3-dimensional analyses, there are three of them and they are
designated S1 (the maximum), S2 and S3 (the minimum). Note that regardless of the orientation of
the stress axes, the sum of the orthogonal stress components is always equal, i.e.:
The converse of these orientations is that in which the shear stress component is maximised (there
is also an orientation in which the shear stress is minimised, but this is ignored since the magnitudes
of the minimum and maximum shear stresses are the same); this is appropriately called the
orientation of maximum shear stress. The maximum shear stress in a three dimensional state of
stress is equal to the difference between the largest and smallest of the principal stresses (S1 and
S3).
The values of the principal and maximum shear stress can be determined through the use of Mohrs
circle. The Mohrs circle analysis can be simplified by neglecting the radial stress component,
therefore considering a less complex (i.e. 2D) state of stress. A Mohrs circle can be developed by
plotting the normal vs. shear stresses for the two known orientations (i.e. longitudinal stress vs.
shear and hoop stress vs. shear), and constructing a circle through the two points. The infinite
combinations of normal and shear stresses around the circle represent the combinations present in
the infinite number of possible orientations of the local stress axes.
A differential element at the outer radius of the pipe (where bending and torsional stresses are
maximised and the radial normal and force-induced shear stresses are usually zero) is subject to 2D
plane stress and thus the principal stress terms can be computed from the following Mohrs circle:
33
. Therefore
the principal stresses S1 and S2 are equal to the centre of the circle, plus or minus the radius
respectively. The principal stresses are calculated as:
*(
*(
and
As noted above, the maximum shear stress present in any orientation is equal to
Radius of Circle
(
(
)
)
or :
34
35
Failure Theories
The calculated stresses are not much use on their own, until they are compared to material
allowables. Material allowable stresses are related to strengths as determined by material uniaxial
tests, therefore calculated stresses must also be related to the uniaxial tensile test. This relationship
can be developed by looking at available failure theories.
There are three generally accepted failure theories which may be used to predict the onset of
yielding in a material:
These theories relate failure in an arbitrary 3D stress state in a material to failure in the stress state
found in a uniaxial tensile test specimen, since it is that test that is most commonly used to
determine the allowable strength of commonly used materials. Failure of a uniaxial tensile test
specimen is deemed to occur when plastic deformation occurs, i.e. when the specimen yields; that
is, release of the load does not result in the specimen returning to its original state.
The three failure theories state:
Von Mises:
Failure occurs when the octahedral shear stress in a body is equal to the octahedral
shear stress at yield in a uniaxial tension test
36
exceeds
Tresca:
Failure occurs when the maximum shear stress in a body is equal to the maximum
shear stress at yield in a uniaxial tension test.
Therefore
37
Failure occurs when the maximum tensile stress in a body is equal to the
maximum tensile stress at yield in a uniaxial tension test
The maximum tensile stress is the largest, positive principal stress, S1 (by definition, S1 is always the
largest of the principal stresses.)
In a uniaxial tensile test specimen at the point of yield:
the uniaxial tensile test. Recapping, the maximum shear stress in a body is given by:
For a differential element at the outer surface of the pipe, the principal stresses were computed
earlier as:
(
As seen previously, the maximum shear stress theory states that during the uniaxial tensile test the
maximum shear stress at failure is equal to one-half of the yield stress, so the following requirement
is necessary:
38
Note that when calculating only the varying stresses for fatigue evaluation purposes, the pressure
components drop out of the equation. If an allowable stress based upon a suitable factor of safety is
used, the Maximum Stress Intensity criterion yields an expression very similar to that specified by
the B31.3 code:
Where:
longitudinal normal stress due to bending
shear stress due to torsion
allowable stress for loading case
Continuing our example for the 6 diameter, standard wall pipe, in which longitudinal, shear and
hoop stresses were calculated:
Assuming that the yield stress of the pipe material is 206 MPa (30,000 psi) at operating temperature,
and a factor of safely of 2/3 is to be used, the following calculations must be made:
The 101.185 MPa is the calculated stress intensity in the pipe wall, while the 137.33 MPa is the
allowable stress intensity for the material at the specified temperature. In this case, the pipe would
appear to be safely loaded under these conditions.
39
to be using in place of
in
Where:
= sustained stress
= intensification factor
= resultant moment due to sustained (primary) loads
= basic allowable material stress at the hot (operating) temperature, as per Appendix A of
B31.1 Code. Sh is roughly defined as the minimum of:
1. of the ultimate tensile strength of the material at operating temperature
2. of the ultimate tensile strength of the material at room temperature
3. 5/8 of the yield strength of the material at operating temperature (90% of the
yield stress for austenitic stainless steels)
4. 5/8 of the yield strength of the material at room temperature (90% of the yield
stress for austenitic stainless steels)
5. 100% of the average stress for a 0.01% creep rate per 1000 hours
40
Where:
= expansion stress range
= resultant range of moments due to expansion (secondary) loads
=
= Allowable expansion stress
= basic allowable material stress at the cold (installation) temperature, as per Appendix A of
B31.1 Code
Occasional:
Where:
= Occasional Stresses
= resultant moment due to occasional loads
=
= occasional load factor
= 1.2 for loads occurring less than 1% of the time
= 1.15 for loads occurring less than 10% of the time.
41
Pipe 1
This exercise will provide further practise with the piping input, and introduce alternative editing
tools which may increase productivity in creating models. We will also investigate and review the
results to see what to look for and see how the piping system is behaving, and how to correct any
issues which may arise during the design.
The first stage of this exercise is to input the model. The model is below; you will also have the same
isometric printed on a separate hand-out in a larger format.
As before with the cantilever example, the model will be input using the node numbering system.
Each section between two nodes is called an element. i.e. node 10 to node 20 are linked together by
an element, referred to by element 10 to 20. Prior to entering geometry, it can be very useful and
is a good idea to mark up the isometric drawing with the intended node number sequence.
We will use a slightly different method of inputting the data, which will allow us to maximise the
graphics area during input. In the main Classic Piping Input, on each area, notice the >> symbol
in the top right corner:
42
Input Model
Enter A106-B as the material, 330C as the temperature and 17 bars as the pressure
The rest of the information we will need to enter for our model can be done via the three windows
we have torn off. Minimise the Classic piping input (of course this can always be maximised at any
point if needed).
Finally we can enter the pipe size and schedule, along with the densities and corrosion allowance, as
per the isometric.
The fluid density can be entered as 0.72SG and CAESAR II will convert this specific gravity to the
correct units. As before the pipe size can be entered as 10 for 10 and S for STD schedule piping.
43
We will begin at the bottom right pipe where it is connected to a pump. This will be node 10.
Note that this is an anchor, a fixed point in our system. Element 10 to 20 is 400mm in length, in the -Z direction. Enter DZ as -400mm
Node 10 is also fixed so we need to specify an anchor. Use the toolbar on the left hand side of the
graphics window (default location) to specify a restraint.
The Auxiliary Data Restraints window will appear. Specify that the anchor is at node 10. The
auxiliary data window can now be closed.
44
Our first element is complete, and should look like the one below:
This next element is a 300# flanged gate valve. We could enter this in a number of ways. The valve
will be rigid relative to the surrounding piping, so must be specified as a rigid element with a
weight. This can be done either as 3 separate elements (flange valve flange), or as one overall
element with the total length and combined weight specified. This can be done manually or by using
the valve flange database to obtain the length/weight automatically from CAESAR IIs catalogue,
which we will do. Select the Valve flange database button and select a gate valve with flanged ends,
class 300.
The Flange Valve Flange check box can be used to split the component into 3 elements
ifrequired.
45
The correct length will be inserted (and the element will continue in the same direction as the
previous element). Also note that the Rigid check box is checked and the rigid weight has been
entered with the relevant weight for a 300# gate valve and flanges. (Hover briefly over the Classic
piping input where it is docked).
46
Enter the DZ as -825mm. This element also leads into a bend, so press the Bend button on the right
hand toolbar. If using the classic piping input we could check the bend check box to achieve the
same result.
The default bend type is a long radius (1.5D) bend This radius can be changed. Common bend radii
are available in the drop down, alternatively any radius required can simply be typed in here.
In addition, further data can also be entered such as if the bend is flanged or mitred etc. Accept the
default long radius bend.
The graphics will not display the bend yet, as there is no following element.
47
This time we are now continuing in the X direction. DX is -1050. The bend will now be visible in the
graphics.
Continue to the next element
This element is a 10x12 concentric reducer and is 203mm in length. Enter DX as -203mm and
specify that this is a reducer.
The Reducer Auxiliary will appear and we can specify further data, including the second end size. A s
before, entering a nominal size in here will be converted to the actual OD. Enter 12 in the diameter
2 and S in the thickness 2 fields, which will be converted to the actual values.
Continue to the next element
Finally continue from the end of the reducer to the centre of the tee, 254mm as shown on the
isometric. DX is -254mm
The model at this point should now resemble the image below, note the node numbers in the image:
48
All elements will turn yellow to indicate that they are currently selected. Ensure all components are
selected.
The Duplicate function can be used to copy, and mirror if required, selected elements.
Duplicate the selected elements and choose to mirror about the Y-Z plane.
We also need to increment the node numbers so that we do not have duplicate nodes.
Currently our model goes from node 10 through to node 70.
If we increase the node numbers by 70, node 10 will become node 80, 20 becomes 90 and so on.
Therefore the second leg will be node 80 through to node 140. The only issue with this is that there
are no common nodes, so the piping will not actually be connected. This can easily be fixed by
chaging node 140 (the centre of the tee on the second leg) to become node 70 (the node at the
centre of the tee on the first leg). This will connect up the piping at the common node, 70 the
centre of the tee.
49
Click OK and the pipe will be duplicated, but as already stated there is no common node so CAESAR II
does not know where to place the pipe. As such it locates it at the origin. The resulting model looks
like the following.
All we need to do is connect element 130 140 to element 60 70. This can be done by changing
140 to become node 70. Select element 140. There are various ways of doing this either double
click in the graphics area, or user the navigation buttons to navigate to the correct element (as this is
the last element the end button will quickly take you to the correct element).
50
Simply change the To node from 140 to 70. The model will now be connected as should look like
the one below:
We can now complete the model by adding the vertical leg and connection to the vessel.
Skip to the last element. This can be done by again using the Last Element navigation button or
using the Ctrl + End buttons on the keyboard.
Click Continue to move to the next element
need to change this to 70 to 140.
51
Click continue and place the final element 140 to 150 in the Z direction, 2000mm. The final
element connects to the vessel, so we will place an anchor at this point. Click the retsraint button
and specify an anchor at node 150
Notice in the isometric that at the vessel connection, there are DY and DZ displacements. These are
due to the thermal expansion of the vessel.
Select the Displacements button and enter in the required values 3mm in DZ and 12mm in DY.
Error Checking
The model is now complete, so run the error checker.
We will receive a fatal error and three warnings. We must correct the errors before we can analyse
the model. The warnings may be acceptable but we should check to confirm that the input is as
intended.
52
Re run the error checker and investigate the warnings. The second two warnings are regarding the
reducer alpha angle which is not specified. CAESAR II is therefore using a default computed value.
This is acceptable here for us.
The first warning is stating that there is a geomtric intersectaion at node 70 (the tee) but we have
not specified a type of tee, and therefore a SIF. This can sometimes be correct but is most often the
result of an oversight, as in this case. Return to the input and locate node 70. The Find tool can be
used to do this:
The Zoom to Node if found check box will also zoom into that node/element if it is found, useful on
larger models.
53
Re-run the error checker. All should now be OK, only the reducer alpha warnings will remain, plus
the C of G report.
Recall from earlier the design code (we are using B31.3) addresses the stresses produced by the
various loads. In our model we have the following loads applied:
Weight
Pressure
Temperature
Displacement
B31.3 requires that two checks are performed Sustained and Expansion
Sustained Weight and Pressure
Expansion Temperature and Displacement
54
Row L1 is an operating case (OPE) and is the Hot case consisting of the real world loads. This case
is not required by B31.3 (although some codes do require this case also). However as this case is a
real world scenario it is used to estalish restraint loads and loads on equipment conections. In
addition, it is used to derive the Expansion case. The expansion case is the algebraic difference
between L1 and L2 (L1 L2).
Accept these load cases and run the analysis by clicking the Running Man icon.
Review Results
After the analysis has run, the output processor will appear. The first thing to notice is that the EXP
case is coloured red. This indicates that this case has failed to code stress check. That is, the
computed stresses in the system at some point are greater than the allowables published in the
code.
We need to fix this.
Select the Expansion case and view the results for the Stresses report.
55
The report shows that the code stress check failed and highlights in red where the check failed.
Double clikcing on any column will order the report by that coluumn. Double click on the Code
Stress column header to order by highest stress.
56
Return to the input and return back to node 70. Pick the Intersection SIF scratchpad and choose
node 70.
Change the unreinforced tee to a reinforced tee. Specify a pad thickness of 10mm
Click the Recalculate button and notice the SIFs reduce dramatically. Now the stresses will be
multplied by 2.887 and 2.415 rather than 4 and 5.
57
From this equation it can be seen that the dominant factor in the code equation is the bending
moment it is the only factor in the expansion case. So which bending moment is this, Mi, Mo or Mt?
Mt is torsion, Mz and Mi and Mo are inplane and outplane so vary dependant on the location. What
we can see from the results though, is which bending moment is the highest in terms of our axes.
View the Expansion case, Restraint Summary report.
We can see from this report that at nodes 10 and 80, the highest bending moment is the MY
moment, at 116 kN.m. The MX is also rather high at 88 kN.m.
58
So we know what is causing the overstress, but how do we correct this and reduce the bending
moment (and therefore the stress)?
Let us look at the 3D plot to view what is causing the bending moment.
Close the report and view the 3D plot
In the 3D plot window which appears, ensure that the Load case we are viewing is the expansion
case and select to Show the deflected shape. You may need to Adjust the deflection scale to get a
more exaggerated deflected shape.
View the pipe from the bottom, using the standard views available
59
We are looking upwards at the pipe from below. The Y axis is pointing upwards (away from us). The
pipe is undergoing thermal expansion and causing the pipe to bend at the anchor points.
Looking at the model from the side view will also explain the MX moment. As can be seen, the riser
is expanding causing the MX bending moment.
If we could add some flexibility in to the area where the pipe is expanding we can absorb some of
this expansion, and so reduce the bending moment. We have the top leg which is flexible, but the
bottom leg is not flexible enough.
60
If we can transfer some of the flexibility in A to B then we may solve the problem.
To do this, increase the length of B by 1m and so consequently reduce the length of A by 1m. This
should give us more flexibility at the bottom, hopefully without removing too much flexibility at the
top.
Return to the input and select element 30 to 40. The DZ value here is 825mm. Edit this to 1825mm.
61
62
63
Supt 01
This exercise is designed to demonstrate adding supports in CAESAR II and demonstrate the
Operating case and Restraint load reports and give an indication of what the results mean on the
restraint load report, along with a short example on how to combat issues with supports, such as
lift off.
The model shown above will also be in your hand-out. Model the piping system as per this
isometric. Anchor at nodes 10 and 90.
64
Locating Supports
The system is anchored at the termination points (nodes 10 and 90), but we also need to support the
weight of the piping system as well.
If both supports are pinned (free to rotate), standard beam theory states that the max moment is at
the centre of the span, l.
If both ends are fixed then the max moment is at the end of the span
Where
As piping systems are neither one nor the other and tend to be somewhere in the middle, a
compromise therefore is reached with an approximation thus;
Taking into account the maximum moment could be somewhere between the ends and the centre
i.e. anywhere along the span.
65
He maximum moment here is located at the end nearer the load, and has a value of
In either case (or in some case in between) the additional stress (M/Z) due to the concentrated loads
should be added to the stress from the uniform load in order to determine the total stress.
Examining the formulas above, it can be seen that as the shorter span (b) approaches zero in length,
the moment, and therefore the stresses approach zero as well.
So, if supports are located as close as possible to concentrated loads, the effects of these loads are
reduced as much as possible.
66
As this calculation will need to be done often, in order to save time calculating
the Manufacturer
Standardisation Society of the Valve and Fitting Industry has calculated allowable piping spans for
various configurations. These standard spans have been published and are shown on the next page.
These spans assume:
It is rare that piping systems are only horizontal runs with no changes in direction etc.; therefore a
caveat is taken in that changes in direction reduce the allowable span to of the standard span.
In addition, the standard span does not apply to risers, since no moment (thus no stress) develops,
regardless of length. However it is preferable to locate supports above the centre of gravity of the
riser to prevent toppling.
These rules here are simply rules of thumb and can provide a good start point for support locations.
Of course, supports should be located with practical considerations taken into account (locations of
building steel/pipe racks etc.).
67
68
We will locate this support close to the valve (node 60). Specify to break the pipe and insert the new
node, number 57, 150mm from node 60:
69
The element will be broken and a new node inserted close to the valve. Locate a +Y support at this
node 57.
The +Y support will support the pipe from below, and will allow movement in the +Y direction.
70
The piping after the bend is 13715mm before the riser. This can almost be split in two exactly with
our 7m span spacing. Remember that the standard span does not apply to risers, and as mentioned
before we will support the riser from the top, rather than trying to balance it from the bottom. As
such we can locate a support near the middle of the 13715mm run, and one close to the bend (node
30).
Break element 30 to 40 and locate a new node number 33. Locate this 600mm from node 30.
It is possible to add a support in at the new node location. We wish to add a +Y support at node 33,
exactly the same support configuration as at node 57. So typing in 57 in the Get Support from
Node field will place the same support as at 57 at our new node 33.
71
Continue on after the riser. There is already a restraint next to the valve, so we have fulfilled the
minimum span up to the valve. After the valve we have horizontal pipe with a bend again.
Therefore our maximum span is 5.25m. The length of pipe is 4115mm and then 3640mm after the
bend. There is an anchor at the end, so we just need one more support between the valve and the
anchor at the end of the pipe.
Locate this support on element 70 to 80, close to the bend at node 80. Locate this 600mm from the
bend.
Break element 70 to 80 and create a new node 77, 600mm from node 80 and with a +Y support the
same as before.
72
Finally the piping riser needs to be supported. The length of horizontal run at the top and bottom of
the riser is less than our span of 7000mm. There is no bending in the riser so in theory we can place
a single restraint near the top of the riser.
Break element 40-50 and locate a +Y restraint 600mm from the tangent intersection point of the
bend. Note that, although this support should satisfy our bending requirements on the horizontal
sections, it may have a very large load since it will also support the whole of the riser.
73
The system is now supported as per the maximum span requirements. We can be sure that the
sustained stress case therefore is acceptable, and should be in the order of approximately 10MPa.
Error Check the model.
You should receive only the Centre of Gravity report, and no errors or warnings.
74
Analyse
Access the Static load cases create only a single load case with weight only. We wish to check the
support locations we have just placed are below the acceptable limits
75
The highest stress level is 10.7MPa, which is almost exactly at the allowable from the standard span
limit (this limit is based on an allowable of 1500 psi ~10.3MPa). The system is supported from a
purely weight induced stress perspective.
We can also now view the restraint loads to see how the weight loads are distributed. View the
Restraint Summary report.
76
Run the analysis and view the sustained stresses. These will have increased slightly due to the fact
that we are now including the pressure term; however the stresses are still well within the
allowables determined by the code.
Similarly the Expansion Case stresses are also very low and well within the allowable the system is
flexible unlike the PIPE1 example.
Now we can check the restraint loads in the real world operating case. Remember the Operating
case is not required by the code, but it does represent the actual loads in a real world scenario, for
the purpose of designing restraints.
View the Operating case Restraint Summary.
77
The loads are different to before as we have included the effects of thermal expansion.
The load on node 77 is 0 (in the FY). This shows that this restraint is not taking any load. What is
happening here?
View the displacements report to see what is happening at this point.
At node 77 the pipe is moving upwards 2.3mm. Also notice that at node 50 (the bottom of the riser)
the pipe is moving down 26mm.
78
View the deflected shape (you may wish to increase the deflection scale to exaggerate the deflected
shape)
The 3D plot shows that the thermal expansion is causing the riser to expand downwards at the
bottom (node 50). This in turn is causing the pipe to pivot at node 57 giving the large operating
load at node 57. The pipe pivoting at 57 causes lift off at node 77 so we see a 0 load.
The restraint at the top of the riser (at 43) is the datum point of expansion and so all the thermal
expansion is from this point. That is why there is no expansion at the top and a lot of expansion at
the bottom. We need to rectify this situation.
79
Fix Model
As we know, the riser is expanding due to thermal expansion. The datum point for this expansion is
the support located at node 43, at the top of the riser, so all the expansion is going downwards
causing the lift off issue. To rectify this we can attempt to move the datum point of the expansion,
so that the expansion is more evenly distributed.
Insert an additional restraint on the riser. Call this node number 45 and locate this restraint 6000mm
below node 43. Insert another +Y support at this location. This should have two effects:
1. Give a better distribution of
the weight loads of the riser
2. Cause less thermal expansion
downwards at node 50.
Re-run the analysis, the batch run command can be used as we have only made a small change by
adding a support.
Review the stresses is the SUS and EXP cases. These stresses should still be acceptable.
80
The sustained case shows that we have a better distribution of the weight of the pipe on the riser, as
the new restraint is taking some load. The load on node 43 at the top of the riser is now distributed
between 43 and 45 (43 has dropped from 30kN to 9kN).
81
The operating case however still shows lift zero load at node 77, and now also zero load at node 43.
Checking the displacements also confirms this; there is still a positive displacement at nodes 77 and
now at 43. Node 50 is still moving downwards, although only 15mm now.
82
Rerun the analysis and check that the stress levels have not been adversely affected.
As before, view the SUS and OPE loads on the restraints to see how the new restraint has affected
the analysis.
83
The sustained report shows that we have further improved the weight distribution among the
restraints.
84
The Operating case now shows a negative load on restraint at node 77. There is no more lift off here
at 77. However the operating loads at node 43 and 45 are now zero. All the thermal expansion that
was going downwards with only the one restraint at the top of the riser has now been forced
upwards instead, causing the pipe to lift off at the top of the riser (43 and 45).
The displacements report confirms this
85
So we have a situation where we are supporting the weight of the system adequately in the SUS load
case, but we have an issue with the thermal expansion. If we replace the rigid +Y restraints along
the riser with Variable Spring Hangers (VSH), these hangers should allow thermal growth whilst also
supporting the required weight for the SUS condition.
86
Select the Hanger table as Carpenter & Paterson. Carpenter & Paterson are a UK manufacturer
whose database of available spring hangers is programmed into CAESAR II. CAESAR II will
automatically calculate the required load and movement at the location, and then review the
database to select an appropriate spring for the calculated load and movements.
Notice that 2 hangers are located at this location also. The graphics will not change in CAESAR II, but
this will locate 2 hangers at this location, and the selected spring will be based upon this shared load.
Error check the model. You should now notice two further notes during the error check.
87
The first not simply shows the number of hangers in the job, and how many of these hangers will be
designed by CAESAR II at run time.
The second message states that new load case combinations are required for the hanger design. A
load case for weight loads is required, so that CAESAR II knows how much weight the hanger(s) need
to support. Secondly, a hanger design operating case is required. This case determines the thermal
expansion at each restraint location to determine the movement at the spring hanger locations as
well. The values of weight from the previous weight load case are used. These two cases together
are used by CAESAR IIs spring selection algorithm to select the appropriate spring from the in-built
catalogue.
Access the load case editor to create these new load cases.
Click the Recommend button in the load case editor. CAESAR II knows that there are hangers
present that require designing, so will recommend the correct load cases for hanger design cases 1
and 2.
Accept these cases. Note the stress type for these cases are HGR type. The results for these hanger
cases are supressed by default (theses are pre-analysis cases and the figures do not actually mean
anything other than for the spring hanger selection).
Case 1 W (HGR)
This case performs a Weight Analysis only with all support locations as rigid restraints. This tells the
spring selection algorithm how much weight needs to be supported at each location (usually in the
Operating condition)
88
CAESAR II will have selected and sized a spring hanger during the analysis. Check the Hanger Table
with text to view the hanger properties of the selected hanger.
As can be seen, CAESAR II has determined that the hanger will need to support a hot load (i.e. OPE)
of 6723N. There are two springs at this location, so this 6723N is the total load shared between two
supports (i.e. the total load is 6723N x 2).
CAESAR has taken these properties and browsed the inbuilt Carpenter & Paterson database and
selected a DV70 Size 11 spring.
Verify the sustained and expansion stresses these should still be acceptable (13% and 19%).
Now check the OPE restraint loads.
89
The hanger at node 43 is now taking load. This load is 13447N (which is 6723N x 2), however there is
still no load being taken at node 45.
Return to the input and replace the rigid +Y support at node 45 with a spring hanger. As before,
select the Carpenter & Paterson catalogue, and place 2 hangers at this location before re-running
the analysis.
As before the SUS and EXP stresses are acceptable.
The OPE case Restraint summary now shows that all the restraints are taking load. The new spring
hanger is taking some of the load of the riser this is now distributed evenly.
90
CAESAR II has again run the two hanger cases and used the results from these to select appropriate
hangers for placing at the two hanger locations. These can be seen from the Hanger Table with text.
91
Turbo
This exercise will build upon knowledge we have gained so far, and introduce the following new
features.
The model is shown above and is also supplied in the hand-out in a larger format. As can be seen,
this is an inlet and exhaust on a turbine. The turbine itself is anchored to the floor at the anchor
point specified.
To keep modelling simple, we can model the inlet and exhaust as two separate models. These two
models can be combined into a single model later there is a common location at the turbine
anchor point.
We will model this common anchor point location as node number 5. However, we will come back
and model this point last.
92
Model Inlet
Model the inlet pipework, on the first element; change 10 to 20 to 11 to 20. Begin at node 11, the
flange connection to the turbine nozzle, as shown below. Note that node 11 also has an anchor
attached.
Once the inlet piping is complete, return to the first element, 11 to 20. We will now insert an
element before 11 to 20, numbered 5 to 10. Node 5 will be the turbine anchor location. Node 10
will be connected to the anchor at node 11. We will connect these via CNode connections.
As there is an anchor at node 11, this node is fixed in all 6 degrees of freedom. However, the nozzle
connection on the turbine will undergo some movement due to the thermal expansion of the
turbine. Recall previously that we had a similar situation where displacements were specified to
account for a similar situation in PIPE 1 for the vessel thermal expansion. In this case, we do not
know what the thermal expansion is here so we cannot enter the displacements. To apply the
displacements to the nozzle point we will add in an element from the nozzle to the turbine base.
This will be a rigid element with zero weight, and it will have temperature applied (so it will undergo
thermal expansion). This element will also be anchored at the turbine base.
If however we specified this as 5-11 for example, nodes 5 and 11 are both anchored, so cannot move
and all that will happen is we will obtain large forces at nodes 5 and 11. We need a way of
connecting this rigid construction element to node 11 which will allow node 11 to move due to the
expansion of the construction element, but still be fixed as far as the rest of the piping is concerned.
This can be achieved in CAESAR II this using CNodes. A CNode will allow the anchor at node 11 to be
connected to another node indirectly. Essentially, both these points will be at the same location,
but CAESAR II will see these points as separate nodes. Therefore what will happen is that as element
5-10 expands, node 11 will act as an anchor, but as it is connected to node 10, node 11 will move to
wherever node 10 moves to, while still acting as an anchor.
93
Next use the Insert function to insert an element before this element.
This is a rigid element, but leave the weight blank in this case. Also add an anchor at node 5.
94
The zero weight rigid will be inserted and connected to node 11 as above. We now need to specify
the temperature for the rigid, as this will undergo thermal expansion.
Select element 5-10 and double click the >> on the temperature/pressure section to tear off the
Operating Conditions box. Uncheck the Propagate parameters box to ensure that the data entered
here is only entered on this one element, and not the whole model. Enter 200C for T1 and make
sure that no pressure is specified.
95
Display P1.
The rigid construction element should show as unspecified, and the rest of the model should show
as 12 bars.
Continue on. After the reducer, there is a bend. Place a length of pipe 350mm long in the Z
direction, adding a bend to this pipe. Place a corresponding pipe 350mm long in the Y direction
afterwards to complete the bend.
96
97
Combine Models
Save the Turbine exhaust as Turbo_Combined.c2
Select the Include Piping Files button to bring in the Inlet piping to create one single model.
The two models will be combined around node 5 the common node in both files.
98
This is because currently the inlet is simply being referenced and not fully included. Return back to
the combine pipe models screen. As well as the File name field, there are three other columns.
RotY allows the included file to be rotated by a specified angle about the Y axis.
Inc allows the node numbers in the new file to be incremented by a certain value. i.e. if the file
included was 10-20, 20-30 etc., we could increment by 1000 so that the nodes would become 10101020, 1020-1030 etc.
The final column is Include Now? This column allows users to choosing whether to reference or
actually permanently include the file. This can be useful if checking that the file is correct before
including, so any changes required can be done in the original separate model.
If your model looks correct, change Include Now? to Y.
Selecting an element in the inlet side of the piping will now show all the fields to be enabled.
Error Check and analyse the model, use the recommended load cases.
The analysis results should show that the expansion and Sustained stresses are acceptable. Check
the OPE case and note the loads on the nozzles at nodes 11 and 1011.
99
There is a reasonable force on these nozzles, as the anchor points are supporting some of the weight
of the pipe. We will now take these forces and check them against NEMA SM23 to analyse the
turbine to see if the loads on the nozzles are acceptable.
NEMA SM23
The National Electrical Manufacturers Association (NEMA) publishes and maintains a standard SM23
Steam Turbines for Mechanical Drive Service. This standard includes allowable loads that can be
applied safely to our turbine nozzles. CAESAR II incorporates this standard and a separate module
can be used to evaluate nozzles, using calculated loads from the piping analysis (as we have just
done).
Return to the CAESAR II main window. Select the Analysis menu and select the NEMA SM23 option
to load the module. You may need to use the to access the whole menu.
100
The direction cosines are specified as the cosine of the angle of the centreline with the respective
axis. For example, if the centreline was as shown above, 60 from the Z axis and 30 from the Y axis,
the direction cosines would be:
Z = Cos 60 = 0.5
X = Cos 30 = 0.866
Our equipment centreline is along the Z axis, so the angle between the centreline and the Z axis is 0
and the angle between the centreline and the X axis is 90
Therefore the direction cosines are:
Z = Cos 0 = 1
X = Cos 90 = 0
Now we can define the nozzles. Click the Add Nozzle button
101
This point is the distance from the resolution point (face of the exhaust nozzle flange) to the nozzle
at node 11. This is as follows:
DX = +100 -150 = -50 mm
DY = -300 + 500 = +200 mm
DZ = +450 + 50 = 500 mm
The basic nozzle information is input. The final thing to do for this nozzle is to apply the loads on this
nozzle. We already have the loads in the CAESAR II job file that we have just analysed. So these
loads can be imported straight into NEMA SM23 module. Click the Select Loads Job and Load Case
button.
102
Browse to the combined turbine model and select the operating case.
The loads will be imported from the job, these will be the loads at node 11 (as we specified the node
number as 11).
103
The inlet nozzle is now complete. Select to add a new nozzle and enter the Exhaust nozzle details.
As before, import the loads from the OPE case in the combined job file.
Once complete, analyse the model using the Running Man icon.
104
The Inlet and Exhaust both fail the analysis. A closer look at the results shows that the FY and MZ
moments are by far the leading causes of the failure. The FY is 214% of the allowable, while the MZ
is also 182%.
Save and Close the NEMA module and return to the piping input.
Looking at the input, it can be seen that the weight of the piping causing the FY will also clearly
result in the MZ moment being excessive there is very little supporting the weight of the piping
other than the nozzles themselves. The only other supports are on the headers.
We need to support the weight of the pipe. Let us focus on the Exhaust first.
Let us support the weight of the pipe to reduce the FY component. Locate a Y support below the
elbow. This will be node 1039. We have not defined node 1039, only 1030 and 1040; so why 1039?
When building the model, it is built in the following way:
105
These intermediate nodes are added by default at 0 around the bend, and at the mid-point of the
bend. This can be seen in the Bend auxiliary data (single click on the bend check box on element
1030 1040). M is used to designate the mid-point of the bend.
These nodes can be moved to the required location if needed for any reason by simply editing the
angle. But we just wish to add a +Y support under the mid-point of the bend, at node 1039.
Add a +Y at 1039.
106
View the 3D plot to see the reason for this. View the deflected shape (you may need to increase the
deflection scale). From a left view, it can be seen that the expansion is causing the pipe to lift off the
support at node 1039.
The load on node 1011 has not changed. As such there is no need to run another NEMA analysis
the results will be identical. Therefore, return to the input.
107
Re-run the error check and visit the Load cases window. We have added spring hanger into our
model, so we require` the hanger cases to determine the hanger size. Use the recommended load
cases again and analyse.
As before, the SUS and EXP cases are well within the code allowables. Check the restraint summary
for the OPE case.
108
The spring hanger is taking some load now (4800N) and the load on the restraint at 1011 is much
reduced.
Return to the NEMA module and we will re-analyse with our new loads.
Save As on the existing NEMA file, and select Nozzle 2 of 2 the exhaust. The Inlet has not
changed so there is no need to re-import the inlet loads.
Refresh the loads from the current job to import the new changed data.
Once done, rerun the analysis. The exhaust now passes at 79% of the allowable.
109
Return to the NEMA module and Save As this file. Re-import the loads for the inlet nozzle and rerun the NEMA analysis.
The Inlet should now also pass.
The piping system is acceptable in within the code allowables, and the loads on the turbine are also
within the allowables of NEMA SM23.
110
Manifold
This exercise demonstrates multiple load cases can be used along with multiple operating conditions
in order to evaluate various what if scenarios. In addition, the API 610 module is used to evaluate
loads on pumps.
Other features shown include naming nodes and naming load cases to make reviewing the results
easier.
The model below will also be on the hand-out. Notice that the three branch legs are virtually
identical. The input should be setup to take advantage of this trait through the use of the element
duplication facility.
111
Use the duplicate feature to create the remaining two legs for Pumps B and C. Increase the nodes
by 1000 each time.
You will not see the new elements initially, as they will be in the same location as run 10 to 70. Find
elements 1060-1070 and change to 1060-90. Also do the same for 2060-2070 and change to 2060100
The elements will all now be connected. Finish by specifying the bend at node 70.
112
113
T1
T2
T3
T4
P1
P2
P3
P4
D1
D2
D3
D4
Enter the temperatures as follows. The element listing displays the value in red whenever it changes
from the previous value.
Use the graphics to verify that the temperatures are correct. Note that the temperatures do not
simply stop being 120C and suddenly drop to ambient. The way we have entered the temperatures
give a basic approximation of a temperature gradient.
114
T2 Pump A idle
T3 Pump B idle
T4 Pump C idle
115
116
P2 Pump A idle
P3 Pump B idle
P4 Pump C idle
117
D1
D2
D3
D4
Pump A
0.75
0
0.75
0.75
Pump B
0.75
0.75
0
0.75
Pump C
0.75
0.75
0.75
0
The model is now complete. Run the error checker. You should receive 3 notes two on the hanger
design, plus the C of G report.
Correct any errors or warnings you may receive.
Access the Static Load cases. We require a number of load cases now one each for SUS, OPE and
EXP for each of our situations, i.e. 12 cases. Plus we require the hanger design cases. The hangers
should be designed for the system when all pumps are hot.
The recommended cases should satisfy these requirements.
118
In addition, to make it easier to identify the pumps, choose to display the Node Name in the reports
as well as the number. Again, this is accessible via Options menu > Node Name
Verify that the system is within the allowables for B31.3 in all situations, both EXP and SUS.
Also check the OPE loads on the pump nozzle connection.
119
Access the API-610 module from the CAESAR II main window and create a new file for the first
iteration Pump A with all pumps activated.
120
Move to the Input Data tab to specify the data for the pump. Note the API coordinate system is
different from the CAESAR II coordinate system, hence API My aligns with CAESAR II Mz. We are
also only concerned with the Discharge nozzle; as such we do not need to enter any data into the
Suction Nozzle tab or fields.
We wish to evaluate the discharge nozzle. This is pump A, so the nozzle is node 10. Fill in the
correct data for Node 10.
121
Now we need to specify the loads on the discharge nozzle. As before, these loads can be imported
from the analysis just done.
Select Load Case 3 Operating case for all pumps active.
Also, for the analysis, we will assume that the distance from the centreline to the nozzle is zero.
122
All the data has been input, so the analysis can now be run.
123
The results show that Pump A is OK for this condition. However, to determine the worst case, we
must perform the other eleven evaluations.
Repeat the above task for all the remaining pumps.
124
From these results, it can be seen that the local Y moment is failing, and is 262% of the allowable. As
mentioned previously, the API-610 coordinate system is different to the CAESAR II local coordinate
system. The local MY translates to the MZ in CAESAR II.
Return to the piping static output and review the results. View the restraint summary for all the
Operating cases.
125
The datum for the thermal expansion is the line stop at node 80. The expansion at the leg for pump
C is the greatest, and so is causing the higher moment at this point. Similar to the exercise SUPT01,
if we can adjust the datum for thermal expansion, we should be able to reduce the amount of
expansion which is causing the moment on Pump C.
This can be done by moving the line stop from node 80 to node 110.
Remove the Z restraint at node 80 and add a new Z restraint at node 110, then re-run the analysis.
Notice now that the restraint summary shows that Pump C has a much lower MZ now. The loads
have been more evenly distributed (Pumps A and B have slightly greater loads, but these pumps
were OK anyway).
Return to the API 610 module and open the file which failed previously -
126
This time the pump should pass as we have reduced the loads sufficiently
127
Tutor
This exercise will develop various sequences of run evaluate modify workflow to determine the
acceptability of the system. Each of the evaluations of the system will develop another aspect of
CAESAR II.
Once the system is acceptable, we will generate a custom report and stress isometrics.
System parameters
Pipe: 8 diameter, standard wall, ASTM A-53 Gr. B
Analysis temperature: 315C
Analysis pressure: 2 bar
Corrosion allowance: 0.8 mm
Insulation: 75 mm CaSi
Fluid: 0.8SG
Pipe Specification: 150 pound class components
Design Code: B31.3
128
Model the system as shown in the isometric. When modelling the bypass loop, the Close Loop
command can be used if required to connect node 150 to 60. Change the node numbers to 150 and
60 and click the close loop button. CAESAR II will add in an element of the required length
automatically.
129
Calculate the thermal growth of discharge nozzle from pump base point.
Alpha= 0.003832 mm/mm
Displacements therefore:
X=0
Y = 500 x 0.003832 = 1.916 mm
Z = 300 x 0.003832 = 1.1496 mm
No rotational displacements
2. Add a construction element between the nozzle node (10) and the pump base with
appropriate material and temperature.
For this exercise, specify the displacement set for node 10 as above.
130
Node 85
1x (double acting) Y restraint, with a friction coefficient of 0.3
131
The only issue is at node 30, where the stress is 130% of the allowable.
132
Hot Load 1355N, deflection 17mmm cold load 1544N. We need to now see if this is appropriate.
View the Restraint summary for the OPErating and installed (SUS) cases.
133
Look at the operating load and installed load on the pump discharge nozzle (node 10). Typically,
with a spring hanger above the pump, the pump will see a positive (up) load in the cold state and a
negative (down) load in the hot state. Here, the piping pushes down on the pump in both states.
This spring is undersized. Why? The calculated load carried by the spring is based on the overall
distribution of weight between all vertical supports. The interaction of the pump nozzle (anchor),
the spring and the other Y supports has very little load assigned to the hanger location. More
weight is carried by the pump rather than the spring hanger.
Deadweight that is resting on the pump must now be transferred to the hanger. The easy way to do
this is to remove the load-carrying capability of the pump in the initial weight analysis when the
hanger load is first calculated. To do this, CAESAR II allows the restraint to be freed effectively
removing this node from the hanger sizing calculation, so the load is distributed amongst the
remaining support locations.
Return to the input and on the hanger; free the restraint at node 10 in the Y axis:
134
A Carpenter & Paterson DV70 has been selected again, but the hot load has increased to 7000N and
the installed load has increased to 8000N.
Review the restraint summary report to view the pump load (node 10).
The resized spring now pulls up on the pump in the cold position and unloads as the system heats
up. (The riser growth drops the load supplied by the spring.) This spring is much better than in the
first iteration; however it could be improved even more. The hanger data input provides for the
specification of the hanger operating (hot) load:
135
American Petroleum Institute Standard 610 (API 610) sets maximum nozzle loads for pedestal
supported pumps. CAESAR II provides this calculation. Run this analysis with the pump data
provided above and using the discharge loads from this analysis. Since both suction and discharge
nozzles are evaluated together, the Table 4 limits in API 610 can be doubled (see API 610 Annex F).
136
The suction nozzle loads and location have already been given:
Suction is -380 mm in X from pump centre.
Piping load on suction nozzle given as: (4450,-3550,-5340) N and (-4070,-3390,2170) N-m
137
The load in the local Y direction (global Z) is excessive as are all three moment terms. The worst
component is the local My (global Mz) which is almost 10 times the Table 4 limit.
138
The large loads are present in operation but not at installation. Therefore these excessive loads
are caused by the thermal expansion of the system. To reduce these loads we need to increase
system flexibility. There are two options to do this.
1.
2.
The most inexpensive modification would be to provide more modelling detail modelling flexibility
in the system that is not currently included. Welding Research Council Bulleting 297 provides
flexibilities for cylinder cylinder intersections. These flexibilities may be applicable to the vessel
connection at node 110.
Include WRC 297 flexibilities
The vessel nozzle/connection is as follows:
We will use this data even though it is outside the acceptable range
Apply the nozzle flexibility and complete the vessel/nozzle data in the Nozzles input.
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The nozzle node is at 110 (recall that the nozzle is represented by the long weld neck). A valid nozzle
node has only a single element connecting to it (i.e. must have a free end) and also a nozzle node is
not restrained nor does it have any displacements specified. We have displacements applied at
node 110, for the vessel thermal growth. To rectify this we will specify a vessel node and apply the
displacements to the vessel node.
The vessel node is optional and works in a similar way to CNode described earlier. Give the vessel
node a unique number. In this case ours will be 1500. In addition, change the node the
displacements are acting on to 1500 as well.
Fill in the remaining vessel data, including the direction cosine the vessel is vertical (Y) so the Y
direction cosine is 1.
140
The nozzle provides limited axial flexibility, but the longitudinal and circumferential bending
flexibilities appear significant.
Re-analyse the system and again review the results.
Review Results
These changes have not had any effect on the SUS case, and the EXP case is still below the allowable,
in fact the highest stress has now dropped slightly - as we have added more flexibility in the model.
The selected spring hanger is still a Carpenter & Paterson DV70, but the hot load has increased by
around 40N.
However, we were previously concerned with the pump loads. Review the OPE case restraint
summary. The loads on the pump (node 10) have now decreased.
141
The values have decreased slightly, but still the discharge nozzle fails.
142
The thermal growth of the long Z run from 80-90 loads the guide and pushes the elbow at node 70 in
the positive Z direction. This thermal growth increases both the pump load in Z and the bending
moment about X. Is the structure guiding the pipe as rigid as the CAESAR II model says it is? If the
guide has lower stiffness, the pump loads may reduce within their allowed limits. There may be
reason, then, to model the structural steel that is interacting with this piping system.
There are two structures a frame under Node 75 and a T pole under Node 85. These structures will
be included in the analysis.
143
The structural wizard will guide you through the process of setting up the structural file.
First the units to be used must be specified. Ensure that the Training units (TRAIN.FIL) are selected
here. Click Next
On next screen, the vertical axis should be selected for the model, either the Y or Z axis can be set to
vertical. Select the Y axis as vertical and click Next
144
The following screen is to specify the steel members to be used in the structural model. Each steel
member is identified by a section ID and can be either selected from an included database of
sections, or can be User defined.
In the structural modeller, each element can be assigned a section ID as well as a material ID.
We will use I-Beams in our model and will select from the built in database. Choose the Select
Section ID button and select the following I-Beams
Section ID 1:
Section ID 2:
W8 x 31
W6 x 20
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The final stage of the structural modeller wizard is to specify the method of element definition.
There are two options for this.
Method One - EDIM method, which is similar in concept to how piping elements are defined a
start node and an end node are specified, along with the distance between the two to define the
structural elements.
Method Two Node/Element method is a slightly different concept. Nodes are added and are
located at points in 3D space. Elements are then defined and users specify the nodes which each
element connects.
Select Method one and click Finish.
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Now we will define the structure. As we have used the wizard to define the material and section IDs,
the next items we can define are the elements themselves. Use the EDim button to add a new entry
to the card stack.
From the sketch we can see that starting at node 2000, there are two vertical steel members, both
2500mm in length. These two members can actually be defined in one entry into the card stack as
they are identical.
Expand the new row in the Card Stack and first enter the From and To node numbers as 2000 and
2010. Also enter dy as 2500. Specify the section ID and Material ID for this section also. Section ID
is 1 and Material ID, as there is only 1 is 1. We now have one element, from Node 2000 to 2010,
2500mm in length in the vertical (+Y) direction.
The inc, incTo and last fields can be used to duplicate this element quickly without adding a new
entry into the card stack. The inc field will increment the From node, starting with the original
From node. i.e. if we enter 10, the From node on the second element will be 2000 +10 = 2010.
So in this case would connect to the first element. The incTo is the same concept, but using the To
node. The last field is simply the to node on the last element to be defined.
Enter inc and incTo as 10 and the last To node will be 2020.
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Continue and add a second Edim to the card stack. Define element 2010 2012. This time the
section ID 2 will be used.
148
Add the finial members on the top. As these are not identical, they must be defined as separate
entries in the card stack.
149
150
The first thing to note about the T Pole is that it is rotated 90. Add in a rotation angle of 90
151
The remaining horizontal elements will not be rotated 90, so add in another Angle and set this to 0
The remaining horizontal elements will also all be Section ID 2. To save having to specify Section ID 2
for all elements, a default Section ID can be set.
To
1010
1015
1020
DX
-600
300
300
152
Save the T Pole and again ensure that all three check boxes are checked.
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After Clicking OK the steel members will be included in the pipe file, however as there are no
common node points between the pipe and steel, the structural members are simply located at the
origin. We now need to move these structural files into the correct location.
A quick review of the pipe and steel model node numbers shows that pipe node number 75 will be
connected to steel node number 2021 and pipe node 85 will be connected to steel node 1015.
However the centrelines of the steel and pipe are not in contact, rather the bottom of the pipe is
resting on the top of the structure. The pipe and steel can be connected either way; connecting the
bottom of pipe with top of steel will be a more visually pleasing model, and in some cases (e.g.
where friction or a guide is included on larger diameter pipe) the proper contact point will affect the
results.
A dummy rigid element will be built at both support points to offset the pipe above the steel. First
locate element 70-75. INSERT a new element AFTER this element. The new element will be from 75
to 1075 and the distance between these nodes will be -210 mm in Y. Make this a weightless, rigid
element.
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Now return to the element 70-75 and redefine the restraint at node 75 by changing the Node to
1075 and define a CNode (connecting node) of 2021. Now that the pipe to 1075 is in Y, the Guide
must be replaced with a Z restraint (a Guide makes both X & Z on a Y pipe). Be sure to do this for all
restraints at this point.
Repeat this procedure for the restraint at 85, creating a new element 85-1085 and connecting 1085
to 1015.
155
The completed model will show the steel structures supporting the pipe as below.
156
The restraint summary for the OPE case shows a significant reduction on the operating loads on the
pump nozzle.
As before, run these new loads through the API 610 processor (use Refresh Loads button to bring in
the new loads).
The discharge nozzle now shows that only the moment about the Y axis (global Z) exceeds the
allowable limit.
Adding the steel effectively increased the guides gap. This greatly reduced the pivot action and the
resulting pump load.
157
Therefore the loop can be added in the Y or Z direction (perpendicular to X). Which is the best loop
layout?
Layout A - A loop in the Z direction at the end of the X run (node 80)
Layout B A loop in the Y direction at the end of the X run (node 80)
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= stress range in leg j (leg j is orthogonal to the direction of thermal growth to be absorbed)
= Length of leg j
= length of leg i (leg i represents each leg helping to absorb the thermal growth)
We know that
So let 6EI = K
Therefore solving for K using the current M (MZ Bending moment which is 5139 Nm) and Li and Lj
Lj = 4200mm
Li = L1 6205mm & L2 4200mm
Keeping K as a constant, we can attempt to reduce M. To do this we will increase the length of the
leg in the three layouts mentioned previously and recalculate M
The following table and graph summarises this.
Added Loop
Leg (m)
In Z
(Layout A)
0
1
2
3
4
5
5.153
3.591
2.542
1.831
1.343
1.004
In Y
(Layout B)
5.153
5.120
4.902
4.395
3.657
2.865
Riser
(Layout C)
5.153
5.248
4.907
4.326
3.686
3.092
Max Mz
(= 2 * Table 4)
3.525
3.525
3.525
3.525
3.525
3.525
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Moment (KN-m)
Riser
(Layout
C)
In Y
(Layout
B)
In Z
(Layout
A)
Max Mz
(= 2 *
Table 4)
According to the calculation, slightly over 1m run in the Z direction is required, however this simple
equation does not take into account any rigid elements or elbows, nor does it consider any
intermediate supports such as the guide at node 75.
We could insert a loop of 1m in length and continue iterating the model until we find a suitable loop
length. However this can take time and finding an efficient loop design may involve several
iterations, even on a simple setup such as this. CAESAR II provides a Loop Optimisation Wizard to
automatically size and create an expansion loop to get the most efficient loop for the target data.
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The Loop Design Wizard will appear and the data required can be input in order for CAESAR II can
design the expansion loop.
The wizard will create iterations of a loop setup in order to focus in on a specific Stress value or
Restraint load. We wish to reduce the Restraint Load on node 10 to below the allowable for API 610
table 4. We will reduce the load to 3300Nm (currently the load is around 5150Nm).
The loop will be located on what is currently the element 75 80. This will therefore be as in Loop
Layout A.
The final thing to define is the space allowed for locating the loop. A cube of space can be defined
which the loop will fit inside. The Wizard will create the largest loop possible in the available space,
and if this is below the specified target load, the wizard will continue iterating to create the most
efficient loop possible, as close as possible to the target value.
In the Loop Design Wizard, select the OPErating Load Case and choose the target data to be
Restraint Load.
As we already have element 75-80 selected, this element will be selected anyway.
The table will be filled in with the results data. Double Click in the MZ cell on the Node 10 row. This
will fill in the Node and Type fields. Enter 3300 as the data in the Load field.
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Specify the Loop Type as the centre loop type this matches the type A that we have already
determined is the most efficient. The final option in the loop type section will allow the wizard to
evaluate all of the Loop Types and determine the most efficient. This takes longer as 8 loop types
are defined.
Also in the loop type section, change the Height to Width ratio to <none> to allow the height to vary
as needed.
Finally the space available for the loop must be specified. Click the Draw Cube button. A cube of
space will be shown in the model. Currently this will be facing the wrong way. Click and Drag the
point labelled PT3 to reposition the cube in the correct orientation. On doing this the Major
Direction field will change to Z. Increase the size of the cube in the Z direction to ensure that
there is enough room to design the loop.
162
Once finished, click Design. The wizard will run through a number of iterations and converge on the
defined target value.
Once complete the loop will be added into the model automatically. A confirmation message of the
total length of pipe and number of bends is displayed
163
Code Checks:
SUS Max stress is now 16% at node 68. Node 68 is the top of the riser. Recall how CAESAR II adds
intermediate node points around the bends as discussed in the TURBO example.
EXP Max stress is 34% located at node 78. This node is the far end of the elbow at the start of the
long Z run
Hanger Sizing:
Carpenter & Paterson DV70 size 11 hanger is still selected. The hot load has decreased slightly.
Pump Load:
The loads on Node 10 look much better now:
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This time all loads pass on the discharge nozzle. The local My (global Mz) is now 1.85 times the
allowable (we have used the 2x table 4 approach) and so now passes.
We have reduced the load on the pump by adding flexibility into the system in the form of an
expansion loop. The addition of this loop required an extra 1.6metres of space. What if this space
was not available?
165
As such we wish to prevent this horizontal growth from being applied to node 10.
We will include an expansion joint to absorb this horizontal growth. Adding the expansion joint just
above the pump will best absorb this growth.
What type of joint should be used? As we are only trying to absorb movement by lateral deflection
only and there is no axial deflection or relative bending rotations at the joint ends, a tied expansion
joint will be suitable.
First of all we need to know the horizontal deflection that we have to absorb. We will use CAESAR II
to determine this by breaking the system above the pump and viewing the displacements report.
The value we obtain from this can be used to select the number of convolutions in the expansion
joint.
Select node 20 to 10 and change to 21 to 30
The system will now have two sub-systems sharing the same origin. We need to reconnect 20 and
21.
166
We also need to prevent any rotation at this point as well. Specify three rotation restraints (RX., RY,
RZ) at node 21, CNode 20
Leave the transverse directions X & Z free to move. The system near the pump connection should
now look like the following:
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DX = 33.4mm
DZ = 11.446 1.150 = 10.3mm
This results in a relative horizontal displacement of 35mm.
This also shows a Mz moment of 4900Nm. This is quite a high load as the system is completely
free to move in the X and Z direction, resulting in the largest displacement. If we were to introduce
some stiffness (as would be in the expansion joint itself) this displacement would decrease.
Using the Senior Flexonics/Pathway expansion Joint catalogue, we will select a 3.5kg/cm2 class 150,
8 expansion joint. The catalogue shows a 20 convolution expansion joint provides 38.8mm lateral
deflection. This satisfies our requirement. However this expansion joint also adds a lateral stiffness
of 6kg/mm or 58.7N/mm.
If we introduce this stiffness, the deflection would reduce. Reduced deflection drops the required
number of convolutions and, in turn, increases the stiffness between nodes 20 and 21.
This iterative process can continue until the deflection test fails or the pump load becomes too high.
Add the final two restraints (X and Z) between 20 and 21. Set stiffness to 58.7 N/mm
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However, the MY is excessive at over 6000Nm. This moment will also place torsion on the expansion
joint and this torsion may also be excessive.
If this observation did not stop the iteration, how would this process proceed?
Test 16 convolutions - 16 convolutions allow 24.8 mm lateral deflection and has K = 118
N/mm
Check travel limits for the proposed joint and the load limits for the pump.
If 16 convolutions is OK and overall joint lateral translation drops, test a shorter (i.e., fewer
convolutions) joint.
In conclusion, because of the large global My on the pump and the torque on the expansion joint,
the proposed length and location of this joint should be reconsidered.
For the purposes of this exercise, analysis of a 20 convolution, tied expansion joint will be evaluated.
For this length, a tied universal joint would probably be preferred; consult manufacturer for other
options.
169
50 pound
Tied
304SS
20
Slip on (Both Ends)
170
The temperature of the element in question is 315C. Apply this temperature to the joint, which will
subsequently cause the stiffness to be adjusted.
The expansion joint modeller will finally confirm the creation of all the elements to be used in
creation of the joint. The stiffnesses will also be displayed, along with the Allowed Movement.
171
Click build and CAESAR II will attempt to define the expansion joint using the data supplied/obtained
from the catalogue.
172
173
In the report template editor, a new report can be created by adding in all the columns you require.
Any column from any report section can be selected.
The following sections are available. The individual columns from these reports can be added in any
order as required.
174
As well as properties for each individual column, report wide settings can also be set.
The template can be either an individual report (one load case per report) or a summary report
(multiple load cases per report). Or a Code Compliance report (detailed information on calculated
values vs allowable) or a Nozzle check report (Displays nozzle loads if present).
We wish to create a custom report which shows the stresses in the EXP case and the SUS case similar
to the Stresses report. View this report for the EXP and SUS cases.
The issue here is that two reports are created, one for each case.
But we wish to view both cases in one report. This therefore would need to be a Summary report.
View the stress summary report for both of these cases.
This report displays the max stress for each case in one report, but does not display the stresses at
each node, like in the stresses report. We need a summary report which shows data at each node.
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First of all give the report a title Stress Summary with Detail. The report template preview will
update to show this. Also change the Report Type to Summary.
The report itself we wish to be shown in a nicer to read font that Courier. Select Calibri, 11pt text
and align the column text to the centre of the column to ensure everything stays inline.
Now we can add the following columns into the report, in the following order:
1. Bending Stress
2. Torsion Stress
3. SIF in Plane
4. SIF Out Plane
5. Code Stress
6. Allowable Stress
7. Ratio %
8. Piping Code
Enter in the column number next to each column required. Also tick the Show Piping Code check
box.
176
Currently there is no summary table like in the Stress Summary report showing the max stresses.
Insert this into the report as well by checking the Show Highest Stresses check box.
177
The filters dialog allows the data to be filtered on a combination of fields and values. The filters
work using Boolean algebra. As such, if multiple fields are required, you must select whether to
include an AND clause or an OR clause in the Filter options. Additionally, any values entered in the
filter can be either Absolute values the modulus of the value is used (i.e. if =500 is entered, -500
and 500 will be classed as matching the filter)) or Signed values (i.e. if =500 is entered, -500 will
not be a match, but 500 will). The results can also be filtered on node numbers.
The filters can be combined by Fields and Classes. The Classes are the categories and are essentially
each tab in the filters dialog. The fields are the individual fields and are essentially each entry on
each tab. Any filters are only applied if the field filtered on is actually displayed in the report. So if a
restraint load filter of FY > 1000N was applied as a filter, this would not be applied to for example
the displacements report FY is not displayed in the Displacements report.
Create a filter to display, as mentioned previously, all stresses greater than 5%.
178
Click Apply and now review the Stress Summary With Detail custom report for the SUS and EXP
cases.
The report will not show every single element now, only those which have stresses higher than 5%.
Generate Report
As we have seen, there are many reports produced by the CAESAR II analysis. All these reports can
be viewed on screen as we have been doing, or alternatively each report can be sent to Microsoft
Word or Excel, or a text file.
We can produce a full report document of the type which could be submitted along with the analysis
for approval.
For our report we wish to include the following information.
Input Echo
Load Case Report
SUStained Stresses
EXPansion Stresses
OPE & SUS restraint loads
OPE displacements at all nodes
Hanger Table with text
This is a simple procedure and is simply a matter of selecting the reports to publish which contain
the data we require and including them in the Output Viewer Wizard section of the output
processor.
179
The listing options window appears prior to the report being generated, where all input data can be
selected for inclusion in the input echo By default CAESAR II picks the most relevant data depending
on the model input i.e. if WRC nozzle flexibilities are included, this is ticked, if there were no WRC
297 nozzle flexibilities, tis box would be un-ticked by default.
180
Word will load in the background and CAESAR II will publish all the selected data. The results will be
inserted as tables into the Word document.
Once complete, review the Word document. Formatting can be applied as usual within Word.
181
The I-Configure window will currently be empty, as no styles will be set up.
182
There will however be two buttons available; the first of which we are concerned with, in that this
button will be used to create a new Isometric directory. (The second button is simply to connect to
an existing isometric directory).
ISOGEN uses a specific file/folder structure, at the top is the isometric directory. Contained within
the isometric directory is a number of Project directories. Each isometric directory can contain
multiple project directories. Contained with a project directory can be many style directories. As
above, each project directory can contain multiple Style directories.
Within each style directory are a number of files, each of which contain various different data for the
appearance and content of the isometric output (including the format of the output - *.DWG, *.DXF
etc). These files are created by I-Configure. I-Configure reads an XML file on selecting the current
style containing all the settings and then writes these settings to various files which ISOGEN reads
when producing an output.
Choose to create a new Isometric Directory.
We will create a new folder on the E:\ drive in which all the ISOGEN data will be located.
Browse to E:\ and create a new folder called ISOGEN and set this as the Isometric directory.
An additional button is now available which allows us to create the project directory.
Within each project directory there must also be at least one style, so the template styles are
available to choose from.
Name the project TRNProject (spaces are not allowed) and select the Final Basic Style as the only
style to produce (Un-tick all other styles). Change the Name column to Stress-Iso as well.
183
Before we produce isometrics, lets check the output to see what an example isometric would look
like.
Before any style created in I-Configure can be used, it must be exported for use (as discussed above).
Select the Stress-Iso style and click Export Style.
Next we can process a sample file through ISOGEN to get a preview of what the output would look
like with our style. To do this, select the Preview Isogen Output button.
184
A sample output will be produced. Select the Drawing preview.DXF and click View.
The resulting isometric will look like the one below. This is not quite what we want. We are
producing a stress isometric, so we do not need a Bill of Materials, and we also want a different
drawing border.
A sample drawing border already exists; we can use this sample border and turn the bill of materials
off.
Copy and paste the file from E:\Training\Masters\A2StressISOBorder.dxf into the isometric style
directory E:\ISOGEN\TRNPROJECT\Stress Iso.
185
We have now specified our custom drawing frame, as we will not require a Bill of Materials on our
Isometrics, we have a little more space available for the isometric plot. Increase this space by
reducing the drawing margin. Currently the drawing margin on the right hand side is 202mm. The
left margin is only 10mm. Make these equal by changing the RightMargin to 10mm also. ISOGEN is
now allowed to use the space that was previously taken up by the BOM as extra space for the plot.
Finally we must now turn off the Bill of Materials. Still in the Overview tab, select the Material List =
True entry in the tree. Again, this will display the relevant variable in the right hand list. Change this
value to False.
Save the changes and Export the style once again so that we can see the results of these changes.
186
This output looks acceptable. Save and close I-Configure and return to CAESAR II.
I-Configure is now set up and we can now use the ISOGEN module in CAESAR II to annotate and
produce stress isometrics.
187
CAESAR II will open the model for isometric production. Click OK to confirm and continue.
Annotating the model involves simply selecting which data to include in the annotations, and is
simply a matter of ticking the required data. All input data can in included as follows.
188
TRN
001
TRAINING
T1
TUTOR
<enter initials>
From the panel select Input data and choose Node Numbers from the feature drop down list. We
wish to annotate all the node numbers. However, as we have discussed previously, CAESAR II
automatically splits bends and inserts intermediate nodes. We do not wish to annotate these
intermediate nodes. As such, select all nodes except the intermediate bend nodes. These bend
nodes should be as follows:
68
69
79
81
82
83
84
118
119
148
149
Select all nodes except those listed above. If you wish, return to the input and check which nodes
are the intermediate bend nodes on your model.
189
Once completed, select Temperatures from the feature drop down and select T1. Do the same for
Pressure P1.
We can now specify the output data. Select Output tab and pick the SUS load case. Select the Stress
option. The highest stress for the SUS case is on the bend at the hanger (node 70) the stress is
actually at node 68, but this is not selectable in the list. Node 60-70 is selectable and will annotate
correctly. Pick this node.
190
Repeat for the stress in the EXP case. The max stress in the EXP case is at node 78
Next select the Nodal annotations. Annotate the two equipment connections as mentioned
previously.
Node 10 PUMP A CONNECTION
Node 110 VESSEL D CONNECTION
Perform a similar task for the elemental annotations, and annotate
Element 100 110 LWN Flange as Nozzle
Finally enter the project attributes.
191
Select to Use Existing Style as we have already created and configured our isometric style.
192
The annotations and attributes specified will be inserted into the resulting isometric.
The isometric could do with a little tidying up the attributes are not quite correctly positioned. The
colours could also do with some improvement perhaps to make the restraints/hangers stand out
more. All this can be done via I-Configure if required.
193
This job consists of an FRP cooling water header, which decreases from 1800mm diameter to
1500mm diameter to 1200mm diameter to 1050mm diameter as a succession of 750mm diameter
lines tap off it. Modelling this job provides the opportunity for the user to explore the capabilities
that CAESAR II offers for analysing FRP pipe. Additionally static seismic loads will be applied to this
system, illustrating methods using uniform loads and load combinations.
194
Mini level analysis: Although feasible in concept, micro level analysis is not feasible in practice. This
is due to the uncertainty of the arrangement of the glass in the composite -- the thousands of fibres
which may be randomly distributed, semi-randomly oriented (although primarily in a parallel
pattern), and of randomly varying lengths. This condition indicates that a sample can truly be
evaluated only on a statistical basis, thus rendering detailed element analysis inappropriate.
For mini-level analysis, a laminate layer is considered to act as a continuous material, with material
properties and failure modes estimated by averaging them over the assumed cross-sectional
distribution. The assumption regarding the distribution of the fibres can have a marked effect on the
determination of the material parameters; two of the most commonly postulated distributions are
the square and the hexagonal, with the latter generally considered to be a better representation of
randomly distributed fibres.
195
Macro level analysis: Where Mini level analysis provides the means of evaluation of individual
lamina layers, Macro level analysis provides the means of evaluating components made up of
multiple laminate layers. It is based upon the assumption that not only the composite behaves as a
continuum, but that the series of laminate layers acts as a homogenous material with properties
estimated based on the properties of the layer and the winding angle, and that finally, failure criteria
are functions of the level of equivalent stress.
196
||
Where:
||
axis
= transformation matrix orienting axes of layer k to transverse laminate axis
= thickness of laminate layer k
Once composite properties are determined, the component stiffness parameters may be
determined as though it were made of homogenous material i.e., based on component crosssectional and composite material properties, and interaction formulae for normal and shear stresses
can be developed.
197
Where:
This equation can be rearranged, to require only a single new parameter as:
(
Note that in theory, the single parameter (
))
) is identical to Va/h.
198
Where:
= Allowable stress, axial
= Allowable stress, hoop
These terms are expressed in the ISO short term failure envelope:
199
200
Where:
= mean diameter of matching pipe
= reinforced pipe thickness of the matching pipe
= Qualified pressure of the fitting
This is a combination of equations (6) and (7) of the Code.
Qualified stress serves as the long term design hoop assigned to pipe. This qualified stress will be
adjusted by the same terms as pipe to develop a long term hoop design stress. The axial limit is
established through the biaxial stress ratio, r.
For pipe,
) (Equation (12) of the Code). The ISO Code assigns values for r for non-pipe
components in Table 4. Given r and the qualified stress, CAESAR II will calculate sa(0:1) for the
component. CAESAR II requires qualified stress and biaxial stress ratio for bends and joints. Tees
have r=1 so only require a qualified stress. The stress envelope for a non-pipe component is a simple
rectangle bounded by a factored design hoop (or qualified) stress and an axial stress equal to r times
that hoop limit. Note that, for some piping components with relatively large axial strength, r can go
as large as 2 indicating that the component is just as strong axially as it is in hoop for any hoop
stress.
201
202
203
CAESAR IIs material database is not currently configured for orthotropic materials such as FRP.
Therefore, CAESAR IIs orthotropic model must be triggered through use of Material 20 (FRP), with
the material parameters entered explicitly. These parameters include:
Axial Modulus of Elasticity (Ea)
The Ratio (Ea/Eh)Vh/a
Pipe Density
Coefficient of Thermal Expansion
Ratio of Shear Modulus (G) to Axial Modulus (Ea)
FRP Bend Laminate Type
This may become tedious, especially if the same type of FRP material is used frequently. In this case,
the appropriate material parameters may be entered in the CAESAR II Configure/Setup, to be used
automatically whenever Material 20 is used.
204
205
Select the RP properties node and specify the properties of the FRP. This FRP is Wavin55 as
mentioned previously. Select this FRP property data file.
The FRP parameters will update to those set in the FRP data file.
Whilst in the configuration file, also specify a default friction coefficient of 0.15 to represent plastic
on steel/concrete.
206
Create the first element, 10 to 20. Note that this pipe is non-standard 1800mm diameter and also
has non-standard 46mm wall thickness.
The 1.5mm Corrosion layer should also be entered here. This layer will always be used in the weight
and thermal force calculations, but excluded from the pipe strength calculations.
207
208
(as mentioned before, the axes have been switched, so the 2:1 position is now identified by R = 0.5),
and also recall that mentioned previously the values on the graph include service factor f2, 0.67. This
factor also needs removing (i.e. divide all values by 0.67). the 0.67 value will be entered as the
system design factor.
As shown in the graph, the reading for the hoop stress is 84 N/mm2. Therefore the hl(2:1) value is:
By definition, long term axial stress at maximum hoop stress, al(2:1), is half of hl(2:1). Therefore:
The axial tension-only long term strength is shown on the chart above as 41 MPa. Therefore
The joint and fitting data is also discussed above. The Qualified stress Qs will be set to 75 MPa and
for bends r = 1.0 and for tees r = 2. Bends also reference the hoop modulus of elasticity which is
entered here as the Eh/Ea ratio of 1.7.
209
Note that we have not entered al(1:1) or hl(1:1) therefore the simplified envelope will be used.
Complete the first element by adding an anchor at node 10 and continue into the bend.
The bend is a mitred bend and has 2 mitre points. Note that the ISO Code ignores the number of
mitres when calculating the bend SIF and flexibility factor.
210
The branch connection at node 40 (as well as all other branches) is a tee (SIF type 1).
Node 40 (along with nodes 60, 100, 120, 160, 180, 190, and 250) is supported by a +Y
(weight only) support (with friction coefficient of 0.15).
The restraint at node 50 (as well as those at nodes 90, 110, 150, and 170) is combination
guide and +Y (weight only) restraint (with friction coefficient of 0.15).
211
Element 70-80 is a reducer (conical section). It can be modelled as such with the exiting
diameter and thickness set to 1500mm and 38mm.
Element 40-280 is a branch off of the 1800 mm line. Its diameter and thickness should be changed to
750 mm and 25 mm, respectively. (Offsets should be considered here as the actual flexible length of
straight pipe [before the bend] 3600 mm is much smaller than the modelled length 4500 mm
and therefore much stiffer. However, for this layout the effect is minimal [about 5% in terms of
stress] and excluded for simplicity.) The bend at node 280 has 4 mitre points.
After modelling the branch through node 300, that branch can be duplicated via the list processor 5
times (with the node increment set to 30, 60, 90, etc.). It is also necessary to change the branch
intersection nodes to 60 (from 70), 120 (from 130), and 180 (from 190).
The completed model should look as below.
A warning relating to the fact that al(1:1) and hl(1:1) were not entered and so the simplified
envelope will be used is shown, as is a warning about SIFs on the intersections and that the reducer
Alpha was not entered so CAESAR II has calculated this value.
Accept these warnings and access the load case editor.
212
Review Results
ISO 14692 Annex D provides a method for converting torsion and bending moments into hoop and
axial stress terms. These stresses, summed with their pressure counterparts, produce effective hoop
stress and effective axial stress. Terms common to B31 piping flexibility factor and stress
intensification factor are used here too. Stress evaluation will first compare effective hoop stress
to the factored design hoop stress. If this check fails, the hoop stress is reported, otherwise, CAESAR
II will continue with the axial check. The effective hoop stress is used with the design envelope to
pick up the factored design axial stress. The effective axial stress is then compared to the factored
design axial stress. If this check fails, the axial stress is reported, otherwise CAESAR II will print the
cause of the largest (stress/limit) ratio either hoop or axial.
Running this analysis shows that this system stresses are satisfactory. Note the changing allowable
stress from node to node. CAESAR II prints a different allowable depending upon which stress
calculation controls Hoop or Axial.
213
(
[
But:
]
and
Where:
= Component amplification factor, from Table 13.6-1
= 2.5 for piping
= Design elastic response acceleration at short period, from Section 11.4.4
= Component response modification factor, from Table 13.6-1. Use 4.5 for pipes not
in accordance with B31, with bonded joints or use 12 for welded, steel B31 pipe.
= 4.5
= Component importance factor, from Section 13.1.3 (1.5 for life-safety
components, hazardous material containing, or piping is in a Category IV structure
(essential facility); 1.0 for all others).
214
Determine SDS:
From section 11.4.4
Where
= Maximum considered earthquake spectral response accelerations for short period
adjusted for site class effects
And from section 11.4.3
Where:
= Site Coefficient defined in Table 11.4-1
= 1.0
= Mapped spectral accelerations for short periods, from Section 11.4.1
= 1.552 g (see below)
Maps of spectral acceleration are available from several sources (ASCE, IBC, NEHRP, and FEMA). Data
is also available on-line at http://earthquake.usgs.gov/hazards/ using the Java Ground Motion
Parameter Calculator (http://earthquake.usgs.gov/hazards/designmaps/javacalc.php). The location
of this piping system on the coast near Los Angeles is 33.9083 latitude and -118.41045 longitude.
Below is a screen capture from the USGS software. SS for the location of interest is shown;
SS=1.552g.
215
Therefore:
(
[
]
](
216
217
Function
Anchor
+Y
+Y
X, +Y
+Y
X, +Y
+Y
X, +Y, Z
+Y
X, +Y
+Y
X, +Y
+Y
+Y
+Y
Anchor
Anchor
Anchor
Anchor
Anchor
Anchor
Anchor
X-Disp (mm)
26
26
16
16
16
16
16
16
16
16
16
16
16
16
16
0
42
42
42
42
42
42
Z-Disp (mm)
9
9
5
5
5
5
5
5
5
5
5
5
5
5
5
0
14
14
14
14
14
14
Note: Displacements need only be placed on +Y supports if friction loads are considered to be
significant.
218
The static seismic wizard provides input for the various data we have discussed previously.
Recall the following values:
= Component amplification factor, from Table 13.6-1
= 2.5 for piping
= Component response modification factor, from Table 13.6-1. Use 4.5 for pipes not
in accordance with B31, with bonded joints or use 12 for welded, steel B31 pipe.
= 4.5
= Component importance factor, from Section 13.1.3 (1.5 for life-safety
components, hazardous material containing, or piping is in a Category IV structure
(essential facility); 1.0 for all others).
= 1.0
= Height in structure at point of attachment. Here, use the average of elevation of all
8 connections
= 6m
= Average roof height of structure
= 12m
In addition, we have the SS value obtained from the USGS utility = 1.552
Input the data into the Seismic Wizard
219
Node 40
220
We now have the restraints defined, but currently they are defined as displacements at nodes 1010,
1040 and 1300. These nodes do not exist in the model.
We will use these node numbers as cNodes and connect all the restraints to the relevant
displacement at the correct elevation. All restraint nodes at 4.6m elevation must be connected via
Cnode to displacement node 1010. (These are nodes 10 and 18).
Similarly, restraint nodes at 2.8m must connect to 1040 (Nodes 40 240) and nodes at 7.3m
elevation must be connected to 1300 (nodes 300 450).
This is easier to perform using the Restraint List view.
221
You will notice that the graphic plot now looks a little odd. The reason for this is, that by default,
CAESAR II displays the system with Nodes and CNodes at the same point in space. This is fine for
connecting pipe nodes to structure CNodes (like in Tutor) or nozzle nodes to vessel/pump CNodes
(like in Turbo). But in this model, where several restraints reference the same CNode, the display
will still attempt to join all these Nodes and CNodes together, resulting in a nonsense plot. To clean
up the plot and avoid the associated coordinate mismatch error during Error Check, change the
Configuration/Setup parameter Connect Geometry through CNODEs to False.
The plot will not update automatically, so must be done manually. Click the Reset plot button to
refresh the graphics.
222
Re-run the eror check there should be no errors and no new warnings or messages.
223
Note that even though results only need be retained from two load cases (the last two), we are
electing to keep results from all load cases in order to help us debug in the event of an overstress.
Load Cases L10 and L11 are not combined algebraically, rather they are included to compare the
displacements, forces and stresses. Hence why they ar enot added or subtracted, just listed. We
wish to find the worst case load case, so we can get CAESAR II to compare the resluts from each load
case and report the maximum and minimum values.
Select the Load Case Options tab and select SignMin and SignMax for the Combination method for
L10 and L11.
SignMax compares the displacements, forces and stresses and uses the maximum force and
maximum stress value of the cases (i.e. sign is considered in the comparison). Displacements are the
maximum Signed valued of all displacements from each case included in the combination. Similarly
224
Review Results
It can be seen straight away that there is an issue with Cases 4 and 5.
225
Cases 4 and 5 represent the-X,+Y and X,-Y seismic loadings. Now we need to find out which
component of the seismic loadings caused the failure the interial or the displacement. Stress due
to force-based load is a primary load, stress due to strain is a secondary load. Once we find out the
cause we can take the appropriate action to resolve the overstress situation.
An easy way to determine which is the worst cause is to run the components of the load case
individually to see wihich gives the greatest stress.
Return to the load case editor.
Load cases 4 and 5 both consist of W, D1, T1, P1, U1 and U2.
We know that W+D1+T1+P1 is not the cause as the OPE case is perfectly fine. So the culprit must be
one of eiether D1, U1 or U2. Therefore, create three new load cases and assign D1 ,U1 and U2
respectively to each load case.
After re-running the analysis review the code compliance report for the three new cases.
226
This shows that clearly the D1 components is the largest contributer to the overstress, by a long way.
This is a secondary loading, so the solution is to add more flexibility. In this case the fix is actually
very simple and involves simply removing the guide just before node 180 located at node 170.
The system will now pass the stress check.
227
228
OPE
SUS
EXP
B31.1
NO
YES
YES
B31.3
NO
YES
YES
B31.4
YES
YES
YES
B31.8
YES
YES
NO
B31.4 CH IX
YES
YES
NO
B31.8 CH VIII
YES
YES
NO
229
The element can be determined to be 5405 mm long (by clicking the local cosine button) so onethird of that length is 1802.
230
Now move on to the branch, starting with element 30-310. This is an 8 standard schedule pipe. The
temperatures on this element should be restored to T1 = 50 C, T2 = -5 C. The bends on this line are
standard Long Radius. This pipe is now A53 Gr B low carbon steel.
Element 30-310, modelled as is, is deceptively flexible, with a modelled length of 2440 mm, and an
actual length of 1980 mm (since the element really originates at the surface of the 36 header, not
at the centreline). So in reality, its flexibility should only be (1980/2440)3, or roughly 50%, of that
calculated. We could correct this by modelling a weightless rigid from the centreline of the header to
surface of the header (i.e., element 30-305), and then begin modelling the 8 line from that point
(i.e., element 305-310).
This approach has the following problems:
1. Placing the weldolet at node 30, causes no stress intensification on the 8 line (since there is
no stress calculated on the rigid, and no weldolet at node 305).
2. Alternatively placing the weldolet at node 305 intensifies the stress on the 8 line, but
doesnt intensify the stress on the 36 line. Furthermore, the SIF would be both
miscalculated (since CAESAR II would think the header size would be that of the rigid
element) and misapplied (CAESAR II would not be able to determine in-plane from out-plane
since the SIF would be at applied to two co-linear elements).
One solution to this modelling dilemma is to use an OFFSET, in this case modelling a From Offset of
457 mm in the Z-direction. This internally models element 30-310 as a 457 mm long rigid element
connected to a 1980 mm pipe, and transfers all stress calculations out to the true start of the 2440
mm pipe. (Note Offsets may not be entered on bend elements, so in this case, it is first necessary to
break element 30-310 into two elements. Be careful that no elements, after applying Offsets, are
reduced to zero-length. So in this case, enter two elements, 30-305 (DZ = 1000 mm, From Offset Z =
457 mm) and 305-310 (DZ = 1440 mm, long radius bend).
231
Element 370-380 goes underground 685 mm below node 370, so we need a node to indicate where
the above ground/underground transition takes place. The entire element 370-380 can be entered
first, and then the Break command can be used to insert a node 375, 685 mm along the element
length. The temperatures at node 375 should be changed to T1 = 30C, T2 = 10C.
The valve at element 430-440 is supported within a valve pit. Nodes 405 and 445 represent the
buried/non-buried transition.
Element 445-450 (like element 115-120) extends indefinitely, in a straight run, underground. We will
determine the required modelling length later; and use a dummy length of 10,000 mm for now.
The completed model will look like the one shown below:
232
We cannot analyse until this has been corrected. To correct, we can edit the material database to
include properties for the material down to the correct temperature.
233
Material Database
Close the piping input to return to the main window. Access the material database form the Tools
menu.
Search for material 102 (A53 B) (you can search on either term). Notice that there are a number of
entries for A53 B for the various different codes, including for B31.8. Select the B31.8 entry
The lowest temperature for which an expansion coefficient is entered is 0C. The next row down is 73.3C, which has no expansion coefficient. As our temperature in the model is -5, we can see
where we have incomplete data. We could enter in the data here for the missing expansion
coefficient.
Alternatively, using engineering judgement, we can take the material properties for A53 B from
another code where the data is filled in sufficiently and use this in B31.8 code.
234
The material database is stored in two files. One file is CMAT.bin. This stores all the default data
and is read only. Any changes to the material are stored in a separate file called UMAT.UMD. This
file stores any material information which is different to that in CMAT.bin. CAESAR II then uses the
UMAT.UMD file first, and reads any further data from CMAT.bin.
Materials from CMAT.bin cannot be deleted, only those from UMAT.UMD.
If we save the A53 B B31.3 material data for use with B31.8, this will be written to the UMAT
database. The CMAT database will be still the same as it currently is, however the UMAT will be
read in preference to this, and it will act as though the data has been overwritten.
To make this change, simply select the Applicable piping code drop down, and change from B31.3 to
B31.8 and save the material.
Return to the input. You should see a warning stating that the properties for the material A53 B,
code B31.8 have changed in the material database, and given the option to use these new properties
or keep the existing. Select to update the material properties via the No Update button.
235
Run the error check again the material errors will no longer appear. The error checler should show
only the Centre of Gravity report.
236
Allows for the direct input of soil properties. These properties are used to generate first the
stiffnesses on a per length of pipe basis, and then the restraints that simulate the discrete
buried pipe restraint. (Note that any existing restraints in the underground area are deleted
during this process.) CAESAR II supports three different soil modellers one based upon the
published work of Mr. L. C. Peng, plus two others (for clay and granular soils) from the
American Lifelines Alliance.
Automatically breaks down straight and curved lengths of pipe. CAESAR II uses a three Zone
concept to break down straight and curved sections. Those ends of pipe identified as
transverse bearing lengths are broken down into Zone 1 lengths (the smallest element
lengths selected to properly distribute the lateral forces to the soil). At distances far away
from Zone 1 are Zone 3 lengths (long lengths of pipe selected to transmit axial loads).
Between Zone 1 and Zone 3 is Zone 2 (transition lengths which vary linearly from the Zone 1
end to the Zone 3 end).
Allows for the direct input of users soil stiffnesses on a per-length of pipe basis. Input
parameters include axial, transverse, upward, and downward stiffnesses, as well as ultimate
loads. The user can specify user-defined stiffnesses separately, or in conjunction with
CAESAR IIs automatically generated soil stiffnesses.
Restraint Parameters
The Underground Pipe Modeller allows the use of any of three different soil modelling algorithms.
The first two are based upon the work of the American Lifelines Alliance, as published in their
document Guidelines for the Design of Buried Steel Pipe, dated July, 2001 (with addenda through
February 2005); this document offers different models for clay soils and granular (sand/gravel). The
third model is based on the soil restraint modelling algorithm presented by L.C. Peng in his two-part
paper entitled Stress Analysis Methods for Underground Pipelines, published in 1978 in Pipeline
Industry. Soil supports are modelled as bilinear restraints having an initial stiffness, an ultimate load,
and a yield stiffness. The yield stiffness is typically set close to zero, i.e. once the ultimate load on the
soil is reached there is no further increase in load even though the displacement may continue. The
basic ultimate loads that must be calculated to analyse buried pipe are the axial and three bearing
(transverse, upward, and downward) ultimate loads. (Note that for the Peng model, all three bearing
ultimate loads are considered to be identical.) Once the axial and bearing ultimate loads are known,
the stiffness in these directions can be determined by dividing the ultimate load by the yield
displacement. (Researchers have found that the yield displacement is typically related to the buried
depth, the pipe diameter, the soil type, and the load type.) The ultimate loads and stiffnesses
237
The restraint equations use these soil properties to generate ultimate loads and stiffnesses using the
following equations.
Initial restraint stiffness is estimated by assuming that the Ultimate Load is developed over a Yield
Displacement (YD). Axial Stiffness (KAX) on a per-length of pipe basis:
238
Where:
=
=
= 6.752
= 0.065
= -11.063
= 7.119
= height of soil cover (measured to centre of pipe, note CAESAR II requests distance
to top of pipe)
Downward Ultimate Load (FD), per unit length
Where:
= 5.14
= 1.0 (for clay)
= defective density of soil (taking buoyancy into account)
Upward Ultimate Load (FU), per unit length
Where:
239
Where:
= coefficient of pressure at rest (dimensionless) = 1 sin
= interface angle of friction for pipe and soil = f
Concrete
1.0
Coal Tar
0.9
Rough Steel
0.8
Smooth Steel
0.7
0.6
Polyethylene
0.5
Where:
=
A, B, C, D, E based on , according to the following table:
20
25
A
2.399
3.332
B
0.439
0.839
C
-0.30
-0.090
D
1.059E-3
5.606E-3
E
-1.754E-5
-1.319E-4
240
4.565
6.816
10.959
17.658
1.234
2.019
1.783
3.309
-0.089
-0.146
-0.045
-0.048
4.275E-3
7.651E-3
5.425E-3
6.44E-3
-9.159E-5
-1.683E-4
-1.153E-4
-1.299E-4
Where:
=
=
= density of dry soil
Upward Ultimate Load (FU), per unit length
dense sand
loose sand
Where:
=
Meshing Parameters
Typical buried pipe displacements are considerably different than similar above ground
displacements. Buried pipe deforms laterally in areas immediately adjacent to changes in directions
(i.e. bends and tees); in areas far removed from bends and tees the deformation is primarily axial.
The optimal size of an element (i.e., the distance between a single FROM and a TO node) is very
dependent on which of these deformation patterns is to be modelled. Where the deformation is
lateral smaller elements are needed to properly distribute the forces from the pipe to the soil. The
length over which the pipe deflects laterally is termed the lateral bearing length (Lb) and can be
calculated by the equation:
(
Where:
= Pipe modulus of elasticity
= Pipe moment of inertia
241
242
Using the (ALA Sand Model), the Axial Ultimate Load (FAX) per unit length is:
] *
This value can be used to determine how long we must model elements 130-140 and 460-470 of the
GASTRANS model. This pipeline is in sandy soil the soil parameters are as follows.
Soil Parameters
Soil Type
Coating Factor (rough steel)
Dry soil density,
Effective Soil density,
Buried Depth, H
Angle of internal friction,
Coefficient of Pressure at rest, K0
Yield Displacement Factor, Axial dT
Yield Displacement Factor, Lat, dP (mult of D):
Yield Displacement Factor, Up, dQu (mult of H):
Yield Displacement Factor, Up, dQu (max mult of D):
Yield Displacement Factor, Down, dQd (mult of D):
Dense Sand
0.8
1909 kg/cm3
1190 kg/cm3
915mm (36 pipe)
610mm (8 pipe)
35
0.426
2.5mm
0.1
0.01
0.1
0.1
243
Bury Pipe
We will now bury the pipe. Close the piping input and return to the main window. Access the
Buried pipe modeller
As soon as the buried pipe modeller is opened, the job file is saved as a copy with the same name
with suffix B
244
We will use the American Lifelines Alliance Sand method. Notice that this is soil model number 2.
Soil model number 1 is reserved for a completely user defined stiffness which can be entered in the
main spread sheet.
245
Now that the soil models have been created, we must specify where/how the system is buried. This
is done in the main Buried Element description Spread sheet.
This spread sheet is used to indicate where the pipe is buried, under which soil type, which mesh
type should be used, as well as any user-defined stiffnesses. A critical part of the modelling of an
underground piping system is the proper definition of Zone 1 (or lateral) bearing regions. These
regions primarily occur:
246
Continuing on, the pipe re-enters the soil at node 115 through to the VAL at node 120.
Next moving on to the 8 pipe line, the pipe enters the soil at node 375, into soil model 3 and
remains in the soil until it exits at node 405 at the next valve pit. The one 1 meshes at the bends will
be automatically added, we only need to define these at the entry and exit points.
The pipe re-enters the soil at node 445 through to the VAL at node 450. Nodes 50 through to the
end are the bypass, and so are above ground.
247
After completing the spread sheet, the model can be buried using the Convert Input function.
You will receive a warning during the conversion stating that any user defined intermediate nodes n
bends will be deleted CAESAR II will re-specify these as per the soil meshing algorithm during
conversion. Accept this message.
The model will finish converting and will confirm that there were warnings we only had the one
which is OK.
Clicking OK will close the buried pipe modeller. The currently selected c2 job file is now the buried
pipe model - GASTRANSB. This is identical to any other c2 job file, the only difference between this
model and the unburied model is the inclusion of a number of restraints with the correct stiffness
added as per the soil models input. Return to the piping input to view the updated buried model.
248
This load case setup requires some minor modification. We need to add a third expansion check on
the stress range between operating case 1 and 2, along with a baseline for these expansion cases, of
the weight no contents of the pipe, which will be used rather than the sustained case. Add the
following load cases:
L3
L7
WNC
L1 L2
249
Also give the load cases meaningful names in the Load Case Options tab
Results Review
The results show that there are failures in the expansion case 6. A review of the code compliance
report shows that the shakedown stresses on the weld-o-lets branch runs at 30 and 50 are
overstressed. The sustained stress is also quite high at these outlets. The range from operating case
1 to operating case 2 is insignificant.
Turning on the stress filter to display only nodes greater than 90 per cent of the allowable reduces
this report to only the branches at nodes 30 and 50:
Reducing these stresses will be left as a follow-up exercise. Now move on to the fatigue evaluation.
250
Fatigue
Due to the danger of gas leaks, and the presence of cyclic loading (pressure fluctuations and solar
heat/cooling cycles) this system is being evaluated for fatigue failures. Since B31.8 does not offer any
specific guidance on fatigue analysis, our best course of action is to calculate the cyclic stresses
according to the Stress Intensity equation, and compare them to ASME Section VIII Division 2 fatigue
curves (Figure 5.110.1), using an appropriate factor of safety.
This system should be evaluated for the following load cases:
Design life: 40 years
Temperature variations:
Ambient temperature: 21C
Summer maximum temperature, above ground: 50C (for 40 years) (T1)
Summer maximum temperature, below ground: 30C (for 40 years) (T1)
Winter minimum temperature, above ground: -5C (for 40 years) (T2)
Winter minimum temperature, below ground: 10C (for 40 years) (T2)
Daily temperature variation, above ground: 20C from extreme (14,600 days) (T3=T1-,
T4=T2+)
Daily temperature variation, below ground: 10C from extreme (14,600 days) (T3=T1-,
T4=T2+)
Pressure variations:
Maximum pressure: 80 bar (P1)
Annual shutdown: 0 bar (40 times)
Minimum operating pressure: 63 bar, varies between 63 and 80 (1,000 occurrences) (P2)
Daily fluctuation: 5 bar drop (14,600 days) (P3=P1-)
Setting up the Fatigue Load cases
Fatigue loads are incurred by transitioning between two or more different operating cases. It is
usually best to model the two extreme load cases, and set up all fatigue load cases to be a variation
from one of these. For example:
Operating Case A: Shutdown, winter minimum (extreme stress condition)
Operating Case B: Full pressure, summer maximum (extreme stress condition)
Operating Case C: Full pressure, winter minimum (enveloped in A-B cycle)
Operating Case D: Compressor operation, winter minimum
Operating Case E: Compressor operation, summer minimum fluctuation
Operating Case F: Pressure fluctuation, winter minimum
Operating Case G: Pressure fluctuation, summer minimum fluctuation
Operating Case H: Full pressure, winter maximum fluctuation
This translates into operating conditions of:
T1 = 50 AG, 30 BG (summer maximum)
T2 = -5 AG, 10 BG (winter minimum)
T3 = 30 AG, 20 BG (summer minimum)
T4 = 15 AG, 20 BG (winter maximum)
251
Before fatigue stresses can be checked, the allowable limits must be defined in the input. Return to
the first element and click on the Fatigue Curves button at the bottom of the Auxiliary Data Area for
Allowable Stress. Fatigue data may be typed in by hand but it may also be read from data files
supplied with CAESAR II or built and stored on the hard drive. Select the 5-110-1B.FAT file to use the
steel fatigue data for B31.8.
252
253
Riser
254
Diameter
Thickness
Temperature
Pressure
Fluid
Riser Jacket
Product Core
Injection Core
18
6
4
Standard
Standard
Standard
15C
80C
95C
0 bar
5 bar
10 bar
0
0.85 SG
1.025 SG
Marine
Growth
50mm
0
0
The 4" injection line is used to inject water into the well to assist in product recovery. The oil is
recovered and pumped to the surface in the 6" product line. The 18" jacket pipe is used to house the
riser tubes, offering protection and support.
This system is installed in shallow water, and subjected to a specified wave train. The objective of
the analysis is to determine the loads and stresses on the system in accordance with ASME B31.4
Chapter IX.
The wave parameters are defined in the table below:
Item
Height
Period
Depth
Wave Theory
Value
5700mm
7.72 sec
9000mm
Stokes 5th
Modelling
The first thing you may notice on the sketch is that the node increment in this model is 5 rather than
10 as in all the previous models. As such we will adjust the node increment for this model. This
change affects this model only. Alternatively the configuration file can be changed if all models
should have a different node increment.
255
256
Continue to the next element. As the isometric shows, the riser continues in 1500mm sections, right
the way up to node 470 at the top. We can create this all in one element, and break to split up into
the 1500mm sections. Change the node numbers to 415 470. The pipe travels 16500mm in the Y
direction overall.
Now we can break this element with a node increment of 5. Use the break command as before, but
this time, select the Insert Multiple Nodes radio button.
257
Enter in a node step of 5 the Total Number and Length fields will be calculated automatically. Also
specify the support configuration as at node 415.
Checking the system coordinates in the list processor shows that node 440 is at the surface
(elevation 0), and there are 12 vertical elements - 6 above the surface and 6 below the surface.
258
Add a bend at node 470 and change the radius to 203mm as before.
Return to element 410 415 (the bottom element on the riser) and add in a +Y support at node 415
with a CNODE to 414. This is done now because this vertical support should not be duplicated to all
the spider connections.
Complete the riser by adding in the final element (470 475). This is 1500mm in the Z direction
and an anchor is located at node 475.
The injection line is now complete.
259
Change the properties of element 605-610 so that they are correct for the 6 line:
Diameter:
T1:
Fluid Density:
6
80C
0.85SG
Wt/Sch:
P1:
STD
5 bar
260
Jacket
Important Notes When Duplicating Core / Jacket Piping
The diameter is changed after the duplication.
Typically, the core pipe uses long radius elbows, and the jacket uses short radius elbows.
This allows the radii of both the core and the jacket to be the same.
If the jacket contains fluid, its density must be computed such that the unit weight across the
entire jacket inner diameter yields the same weight as the real fluid in the annulus between
the jacket and core pipes.
Core pipes do not see environmental loads. This is important to check after building the
model.
Continue after the last element (670-675) and change the node numbers again. This time for the
18 pipe so use node numbers 1810 to 1870.
This element is 18000mm long
Diameter:
T1:
P1
Fluid density:
Restraints:
18
15C
zero
zero
X
Y
Z
RY
Marine Growth:50mm
Next break this element, using the multiple break function again, and a node increment of 5. This
will split the element into 12 sections, each 1500mm in length.
261
Follow with another dummy rigid element from 1815 to 614; 110 mm in X. This will join the product
line through the restraint at 615 with its CNODE at 614.
The graphics should now display the model correct.
262
Once complete, and all restraints along the riser are defined, run the error checker.
There will be a number of warnings concerning "zero weight" rigid elements and "four elements
framing into a node". These are all acceptable in this instance.
Note that the Centre of Gravity Report shows a combined weight of about 33,000 N. Recall that the
riser is supported only at its base, with a pin connection. In reality, risers are supported by top-side
tensioners, exerting a force sufficient to ensure the riser is always in tension. For this job, return to
the input and at node 1870 (the top of the riser), define a hanger to apply a constant vertical force of
45,000 N.
Re-run the error checker. The model should now be ready for analysis.
263
Hydrodynamic Theory
A basic discussion of hydrodynamic theory can be found in the CAESAR II documentation (Technical
Reference Guide, Chapter 6). There are a variety of different wave theories, used to compute the
water particle velocities and accelerations resulting from a wave train. CAESAR II includes solutions
to the three most commonly used wave theories; Airy, Stokes 5th, and Stream Function. The latter
two theories are non-linear, but provide a better description of the water particle behaviour.
CAESAR II also includes modified versions of these three theories, which allow consideration of the
fluid above the mean sea level.
The basic procedure is to solve for the wave length, based on a selected wave theory. Once the wave
length is known, the velocities and accelerations can be determined at any position in the water
column. Based on these values, drag (Cd), inertia (Cm), and lift (Cl) coefficients are determined for
each pipe element. These coefficients, along with the velocity and acceleration are used to compute
the force applied to the piping elements, using Morrison's equation:
| |
Where:
= fluid density
= drag coefficient
= pipe diameter
= particle velocity
= inertial coefficient
= particle acceleration
The particle velocities and accelerations are vector quantities which include the effects of any
applied waves or currents. In addition to the force imposed by Morrisons equation, piping elements
are also subjected to a lift force and a buoyancy force. The lift force is defined as the force acting
normal to the plane formed by the velocity vector and the elements axis. The lift force is defined as:
Where:
= fluid density
= lift coefficient
= pipe diameter
= particle velocity
The buoyancy force acts upward, and is equal to the weight of the fluid volume displaced by the
element. Once the force on a particular element is available, it is placed in the system load vector
just as any other load is. A standard finite element solution is performed on the system of equations
which describe the piping system.
For this particular model, a sample hand computation will be used to estimate the applied wave
load. This will be used as a verification of the loading, to ensure we are making the correct
assumptions and modelling correctly.
264
Hoop F1
0.72
0.60
Longitudinal F2
0.80
0.80
Combined F3
0.90
0.90
The B31.4 piping code states that the environmental loads used in the analysis correspond to the
"100 year" storm. This is equivalent to the largest storm that occurs every 100 years.
265
Hydrodynamic Input
The hydrodynamic input specification in CAESAR II is relatively simple. Up to four different loading
conditions can be defined. These different conditions could be different waves, currents, or
directions. For each of these loading conditions the data is defined as shown below
This particular load definition is specifies only a wave. However, either a standard current profile or
a current table can also be defined. The particular wave used in this example is a well-publicised
wave, used as the example in the paper by Skjelbreia and Hendricson for the solution to Stokes 5th
Order Gravity Waves. Note this does not correspond to a "100 year storm". This wave is being used
because it has published results.
The wave data consists of the water depth (9 m), the wave height (5.7 m), the wave period (7.72
seconds). The wave kinematics factor is a factor used for Stream Function and Stokes 5th solutions
to account for the spreading of the wave energy in a real sea state. Values typically range from 0.85
to 1.0, and serve to reduce the particle velocities.
The "Phase Data" defines how the wave is imposed on the piping system. Since the wave moves over
the piping system, every element of the system is exposed to every phase of the wave. At one
particular position (phase) of the wave the piping system will experience the maximum
environmental load. Performing 360 solutions to find this maximum is not practical, given the other
factors involved (combination with current, non-uniform sea state, directionality, and spreading).
Typically drag governs the loading on (small) piping system, so the wave is positioned so that most of
the piping system sees a zero phase angle. Alternatively, the input can be set so that the entire
system sees a zero phase angle.
266
Wave Solution
The hydrodynamic parameters as defined in the input are used by the Stokes 5th wave theory to
determine the water particle data. This solution can be evaluated numerically (by reviewing data
tables) or graphically (through the use of plots). A brief evaluation is shown below.
First, two dimensionless parameters are computed and used to determine the "suggested" wave
theory. This evaluation is performed by plotting these dimensionless parameters on a chart, found in
a number of publications. This chart, with the location of the specified wave for this job is shown in
the figure below. This chart (and the remainder of the wave solution) can be obtained using the
Chart Current Results button on the Load Case Editor.
For this particular wave, the chart shows that the recommended wave theory is Stream Function 9th
Order. (This job will still employ the Stokes 5th solution, for illustrative purposes.) Each region of the
chart corresponds to a different wave theory, as detailed in the key at the bottom.
The Drop down list at the top of the dialog box allows other graph representations to be shown.
Select the Surface Elevation vs Phase option
267
This figure shows that the wave crest is at a phase of zero, with the trough at a phase of 180
degrees, as expected. Notice also that the wave profile is not symmetric about the mean water level.
For this 5.7 m wave, the crest is 4 m above the still water level while the trough is 1.5 m below the
still water level. Only the Airy wave theory produces a symmetric wave profile.
268
269
Note that in this plot, the velocity in the trough is shown as zero. This is because the plot is showing
the data at a depth of zero, the still water level. In the trough region, the water is below this level. At
a lower depth, the velocities do go negative, which can be seen by reviewing the actual data tables.
270
Plots such as these are typical of wave solutions. The wave solution produces data for the entire
water depth over the entire wave phase. Horizontal and vertical velocities and accelerations can be
studied as a function of depth or phase. In addition to plotting the data, the actual numerical values
can be reviewed by clicking the View Data Table button. This file is called <jobname>.WV1 and is a
text file so opens in Notepad.
271
Cd versus Re and K
Cl versus Re and K
272
Elevation
(m)
Velocity
(mm/sec)
1810
0
2300
1815
1.5
2370
1820
3
2440
1825
4.5
2615
1830
6
2870
1835
7.5
3235
1840
9
3710
Element Force Computation
Element
1810-1815
1815-1820
1820-1825
1825-1830
1830-1835
1835-1840
Avg.
Velocity
(m/sec)
2.335
2.405
2.528
2.743
3.053
3.473
Acceleration
(m/sec2)
0.00
0.00
0.00
0.00
0.00
0.00
0.00
KeuleganCarpenter
Number
31.87
32.84
33.81
36.23
39.76
44.82
51.40
Reynolds
Number
Cd
Cm
Cl
1.08 E +6
1.11 E +6
1.14 E +6
1.22 E +6
1.34 E +6
1.51 E +6
1.74 E +6
0.661
0.656
0.651
0.639
0.621
0.625
0.631
1.746
1.749
1.751
1.759
1.769
1.765
1.759
0.257
0.250
0.243
0.226
0.202
0.200
0.200
Avg. Cd
Avg. Cl
Diameter
(mm)
Density
(kg/cm3)
0.658
0.653
0.645
0.630
0.623
0.628
0.254
0.247
0.235
0.214
0.201
0.200
557.2
557.2
557.2
557.2
557.2
557.2
0.001025
0.001025
0.001025
0.001025
0.001025
0.001025
Drag
Force (Fd)
(N/mm)
1.025
1.079
1.176
1.353
1.658
2.163
Lift Force
(Fl)
(N/mm)
0.395
0.408
0.428
0.460
0.534
0.689
273
Element
1810-1815
1815-1820
1820-1825
1825-1830
1830-1835
1835-1840
Length
(mm)
1500.00
1500.00
1500.00
1500.00
1500.00
1500.00
Fd
(N)
1537.29
1618.83
1764.72
2029.74
2468.55
3244.27
Fl
(N)
592.13
611.34
642.70
689.51
801.55
1033.02
Notice for these computations, that "average" values are being used for the element velocities and
hydrodynamic coefficients. The CAESAR II program actually computes the exact values at integration
points on each element, from which the "fixed end forces and moments" are determined.
Wind Loading
The default ASCE 95 wind loading procedures will be used on this riser. (This standard states that the
minimum wind pressure is 10 lb/sq.ft. or 0.479 KN/sq.m.) The basic procedure to compute the wind
load on each pipe element is as follows:
Obtain the wind speed (V). From ASCE 95, the Gulf Coast of the U.S. can experience winds of up to
225 km/hr (140 m/hr). API-RP2A recommends a wind velocity of 175 km/hr (109 m/hr) for the Gulf
of Mexico. Assume a wind speed of 55m/sec (123 m/hr) for this job.
Determine the applicable structural category from ASCE 95, Table 1.1. From this table, select
category II (2).
Determine the Importance Factor (I) from ASCE 95, Table 6.2. Based on the selected category, the
Importance factor is 1.0.
Determine the Exposure Category from ASCE 95, Section 6.5.3. For this job, select exposure category
D (flat, unobstructed terrain).
From ASCE 95, Commentary Section 6.5, determine Kz. This term varies by elevation and therefore
may vary from element to element. Constants used in the equations to determine Kz can be
obtained from Table C6-2, based on the exposure category.
Determine Kzt, which is the wind speed-up over hills. For this job, there are no hills, so Kzt is 1.0.
Based on these parameters, compute the velocity pressure as defined in ASCE 95, Section 6.5.1.
This is: qz = 0.613 * Kz * Kzt * V2 * I, where all terms are defined above. For this equation, V is
expressed in meters per second and qz in newton per square meter. (If V is in mph and qz in lbf/ft2,
the constant becomes 0.00256.)
Once qz is known, the force on the element can be determined from: F = qz * Gf * Cf * A, where:
- Gf is the gust response factor
- Cf is the shape factor for the element (defined in the piping input)
- A is the projected wind area of the element (including insulation if specified)
274
275
2/alp
ha
4.6/zg
213.36
213.36
213.36
213.36
213.36
213.36
0.174
0.174
0.174
0.174
0.174
0.174
0.0216
0.0216
0.0216
z/zg
Kz
0.513
0.513
0.513
0.525
0.548
0.568
0.0246
0.0316
0.0387
1.031
1.031
1.031
1.055
1.102
1.142
Velocity Pressures
Element
Kz
1840-1845 1.031
1845-1850 1.031
1850-1855 1.031
1855-1860 1.055
1860-1865 1.102
1865-1870 1.142
V (m/s)
55
55
55
55
55
55
Wind Force
Element
1840-1845
1845-1850
1850-1855
1855-1860
1860-1865
1865-1870
G
0.85
0.85
0.85
0.85
0.85
0.85
qz
1912
1912
1912
1957
2044
2117
Zg
(m)
I
1
1
1
1
1
1
Cf
0.65
0.65
0.65
0.65
0.65
0.65
qz
1912
1912
1912
1957
2044
2117
Af (m2)
0.686
0.686
0.686
0.686
0.686
0.686
= 1.0
Force (N)
725
725
725
741
775
802
276
These load cases can be given more meaningful names in the Load Case options tab
The results for all load cases will be available at the output level, but for the "environmental only"
load cases, only displacements and forces will be presented by the output processor. Load cases #4
and #5 are the Code compliance cases necessary for the stress check. The output status for load case
#1 could have been set to "discard", since in this instance its results are not significant on their own.
However, it may be necessary to evaluate the results of this load case in the event of overloads or
over stressed elements. Therefore the output status is left as "keep".)
277
Analysis
Once the load cases are defined (and the loading data has been checked), the analysis can proceed
as usual. At the output level, the results of the "environmental" load cases should be reviewed to
ensure they agree with the hand computations. For this job, the environmental loads act on the riser
body and are resolved about nodes 1810 and 1870. The restraint summary report details this loading
resolution.
For load cases #2 and #3, summing the FZ loads at nodes 405, 475, 605, 675, 1810 and 1870 yields
the applied environmental loads. These loads are summarised in the table below.
Applied Load Summation (from CAESAR II)
Node
405
475
605
675
1810
1870
Wave
Drag Fz (N)
539
380
1697
1145
6749
2030
Lift Fx (N)
78
85
287
299
2769
810
Wind
Fz (N)
105
200
347
589
631
2620
4328
4492
These loads can be compared to the hand computed results of 12681 N, 4370 N , and 4492 N. This is
an acceptable comparison, given the approximations made in the hand computations.
278
One solution here is to reduce the thermal component of the stress by extending the bottom-side
piping, from 1800 mm to 3000 mm. This drops the stress level to 86.5% of the allowable.
(This job is not intended to be an example of good riser design. The riser tension was arbitrarily
selected to be simply larger than the "air weight" of the riser. Additional vertical supports may be
used along the length of the riser to assist in supporting the core piping. For larger (longer) risers,
external buoyancy chambers are used to offer additional vertical support along the riser body. None
of these concepts are addressed in this example.)
(Fatigue has not been addressed in this example, but is typically a required consideration. For this
job, the fatigue (FAT) case would be defined as "L4-L5" with a specified number of cycles and a
corresponding material fatigue curve.)
279
280
Element 37-40
o Change the from node from 37 to 36
o Edit the length of this element to 1715mm
Node 43
o
281
Element 70-77
o Change the to node to be 72
o Edit the length to be 2000mm
o Edit the support node number to be 72
Element 77-80
o Change the from node to be 72
o Edit the length to be 2115mm
Element 80-90
o Break this element
o Create a new node number 85, located 1000mm from node 80
o Insert a +Y at this location
Where:
D
t
Wave speed & pressure change for water in steel pipe (P/V= c):
D/t C (m/sec) P/V (bar/(m/sec))
20
1310
13.1
40
1210
12.1
60
1130
11.3
80
1065
10.65
Using D / t = 314 / 9.5 = 33, P/ V = approximately 12.45 bar / (m/sec); assume V = 2 m/sec;
so:
282
283
Remember to change the load case combination method to Scalar for the OCC load cases in the load
case options tab.
284
Check Results
There are still issues in the OCC load cases, but
Note that even though the pipe lifts off of the restraint at node 22, the occasional only load, Load
Case 7, does overcome the pre-existing operating load first, for an accurate simulation of events:
The Code Compliance Evaluation shows that the system is still highly overstressed under this OCC
load. This problem can be resolved by adding restraint (since the water hammer is a primary load).
We can use a rigid Z-restraint to contain the water hammer if we can find a point in the vicinity of
the load (run 50-80) where the Z-operating displacement is negligible (so the previous expansion and
sustained analyses will be relatively unaffected). A good candidate is at node 78 as the OPErating
displacement report shows.
285
Correct model
Return to the input and select element 72-80. Node 78 is on the 0 angle of the bend at the to end
of this element.
286
287