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PROCEDURE FOR PUMP LINE ANALYSIS

REQUIRED DOCUMENTS

Pump line ISO, Pump vendor drg, allowable nozzle Load, P& ID, and LDT. In the
absence of allowable load in vendor drg, twice of API-610 values are used.
CAESAR axis system should match with vendor drg or API-610 for comparing
nozzle allowable loads and moments.

PUMP MODELING IN CAESAR-II


Most commonly used centrifugal pumps are:
1. End suction Top discharge
2. Top suction Top discharge
3. Side suction Side discharge
For above mentioned pumps detail modeling procedure in CAESAR-II is discussed as
below
1. End suction Top discharge
Referring to Fig.1, node marking 1-2 shows nozzle flange with given flange
rating as rigid element. Node 2-3 shows nozzle standby with pipe element (dia
equal to pump impeller dia and thickness equal to pipe wall thickness) as rigid
element with zero weight from flange welding joint to pump impeller center line.
Restraints
1) The pipe flange to be get anchored as C- Node with pump flange to get
nozzle load due to piping reaction. This load value should be less than allowable
values.
2) Rigid element at Impeller C/L to be get anchored i.e. anchor at node3.

2. Top suction Top discharge & 3. Side suction Side discharge


Referring to Fig.2 & 3, node marking 1-2 shows nozzle flange with given flange
rating as rigid element. Node 2-3 shows nozzle standby with pipe element (Dia
equal to pump impeller dia and thickness equal to pipe wall thickness) as rigid
element with zero weight from flange welding joint to pump impeller center line.
Node 3-4 shows rigid element with zero weight up to centre line of the pump.
Restraints
1) The pipe flange to be get anchored as C- Node with pump flange to get nozzle load
due to piping reaction. This load value should be less than allowable values.
2) Rigid element at pump C/L to be get anchored i.e. anchor at node4.

LOAD CASES FOR PUMP LINE STRESS ANALYSIS


Load cases for the pump connected lines are discussed below.
1. Hot Cold Load case:
When two or more pumps are used in a system then from stress analysis point
of view the different load cases are made. Like,

Both pump operating.


One pump pump operating & one stand by.
(This point to be get discussed with process, what will be the requirement, whether at
any moment only one pump will operate, for more than two pump case)

Hot Cold analysis to be done at design and operating temperature.


For the pump, which is not operating, ambient temperature should be considered
from Tee point
When two pumps are present in the system hot cold cases can be made as
below (Refer Fig. 4).

Case 1: When both pumps are in operating condition, provide design and operating
temperature for node 10-20-30-40-A & 20-50-60-B
Case 2: When pump A is operating and pump B is cold, provide design and
operating temperature for node 10-20-30-40-A and ambient temperature for 2050-60-B.
Case 3: When pump B is operating and pump A is cold, provide design and
operating temperature for node 10-20-50-60-B and ambient temperature for 2030-40-A.

When three pumps are present in the system hot cold cases can be made as

below (Refer Fig. 5).

Case 1: When three pumps are in operating condition, provide design and operating
temperature for whole system.
Case 2: When pump A is cold and pump B & C are operating, provide design and
operating temperature to node 10-20-30-70-B & 20-50-60-C and ambient
temperature for 30-40-80-A.
Case 3: When pump B is cold and pump A & C are operating, provide design and
operating temperature to node 10-20-30-40-80-A & 20-50-60-C and ambient
temperature for 30-70-B
Case 4: When pump C is cold and pump A & B are operating, provide design and
operating temperature to node 10-20-30-40-80-A & 30-70-B and ambient
temperature for 20-50-60-C.
2. WNC (Weight No Content) Load case:
The basic philosophy for WNC is by what magnitude the piping flange
displaced at the mating point while cold alignment. For WNC case, make the pump
flange anchor node free and replace the spring support to rigid support. Go in load
case spread sheet, drag the WNC from side menu to load case row and select
Sustain case. Run the case and get the displacement at the pump nozzles, this
displacement should be less than 1mm (or consult mechanical department to get
allowable deflection).
3. Load Cases in CAESAR-II for two pump connected system
Load cases for stress analysis of two pump connected piping system are
discussed below. Same philosophy is applicable for more than two pump connected
system.
Abbreviation: W = Weight; T= Temperature; HP = Hydro Pressure; WW = Water
Filled Weight; WNC = Weight No Contents; P = Design Pressure. U1 = Uniform load
(NS Seismic); U2 = Uniform load (NS Seismic);
A. Load Cases for Static Analysis (Two Pumps A & B)
CASE1: WW+HP (HYD)
CASE2: W+P1+T1 (OPE) Both pumps at design temperature.
CASE3: W+P1+T2 (OPE) Both pumps at operating temperature.
CASE4: W+P1+T3 (OPE) Pump A at design temp and Pump B standby.
CASE5: W+P1+T4 (OPE) Pump B at design temp and Pump A standby.

CASE6: W+P1+T5 (OPE) Pump A at operating temp and Pump B standby.


CASE7: W+P1+T6 (OPE) Pump B at operating temp and Pump A standby.
CASE8: W+P1 (SUS)
CASE9: WNC (SUS)
CASE10: L2-L8 (EXP)
CASE11: L3-L8 (EXP)
CASE12: L4-L8 (EXP)
CASE13: L5-L8 (EXP)
CASE14: L6-L8 (EXP)
CASE15: L7-L8 (EXP)

For load case no 2, 3, 4, 5, 6,7and 8 pump nozzle load is checked and it should
be within acceptable limit as specified by vendor or API 610.

For load case no 1, 8, 10, 11,12,13,14 and 15 stress value is checked and it
should be less than allowable stress as specified by relevant code.

For load case no 9 (WNC case) deflection is checked at pipe flange for cold
alignment case as discussed in earlier topic of WNC load case.
B. Load Cases for Static Analysis (Three Pumps A, B & C)
CASE1: WW+HP (HYD)
CASE2: W+P1+T1 (OPE) Three pumps at design temperature.
CASE3: W+P1+T2 (OPE) Three pumps at operating temperature.
CASE4: W+P1+T3 (OPE) .Pump B&C at design temp and Pump A standby.
CASE5: W+P1+T4 (OPE) ..Pump A&C at design temp and Pump B standby.
CASE6: W+P1+T5 (OPE) ..Pump A&B at design temp and Pump C standby.
CASE7: W+P1+T6 (OPE) ..Pump B&C at operating temp and Pump A standby.
CASE8: W+P1+T7 (OPE) ..Pump A&C at operating temp and Pump B standby.
CASE9: W+P1+T8 (OPE) ..Pump A&B at operating temp and Pump C standby.
CASE10: W+P1 (SUS)
CASE11: WNC (SUS)
CASE12: L2-L10 (EXP)
CASE13: L3-L10 (EXP)
CASE14: L4-L10 (EXP)
CASE15: L5-L10 (EXP)

CASE16: L6-L10 (EXP)


CASE17: L7-L10 (EXP)
CASE18: L8-L10 (EXP)
CASE19: L9-L10 (EXP)

For load case no 2, 3, 4, 5, 6, 7, 8, 9 and 10, pump nozzle load is checked and it
should be within acceptable limit as specified by vendor or API 610.

For load case no 1, 10, 12, 13, 14, 15, 16, 17, 18 and 19 stress value is checked
and it should be less than allowable stress as specified by relevant code.

For load case no 11 (WNC case) deflection is checked at pipe flange for cold
alignment case as discussed in earlier topic of WNC load case.
C. Load Cases for Seismic Analysis:
For seismic stress analysis make separate file as FILE NAME_sei. In this file
remove design and operating temperature and enter ambient temperature as T1.
Replace all +Y restraint by Y restraint. Remove all friction and guide gap at
restraints. Click on uniform load in CAESAR spread sheet and enter 0.34 value in UX
and UZ direction. Activate uniform load in Gs option in Kaux special execution
parameters. Make load cases as below:
CASE1: W+P1 (SUS)
CASE2: U1 (OCC)
CASE3: U2 (OCC)
CASE4: L1+L2 (OCC)
CASE5: L1+L3 (OCC)

For load case no 4 and 5 stress value is checked and it should be less than
allowable stress as specified by relevant code.

IMPORTANT POINTS TO BE CONSIDERED:

Strainer at suction line should be modeled with actual weight.

First support from the pump nozzle should be of adjustable type support. If first

support is spring then it should be locked and adjustable for alignment of pump.

Closed drain piping to be modeled for even 2 or below near pump nozzle.
Frictions to be given properly on all point from pump to header at least.

All rigid element weight to be considered while modeling e.g. valves, flanges etc.