Must have Load cases for stress analysis of a typical piping

system using Caesar II

The main objectives of stress analysis is to ensure
A. Structural Integrity (Design adequacy for the pressure of the carrying
fluid,Failure against various loading in the life cycle and Limiting stresses below
code allowable.)
B. Operational Integrity (Limiting nozzle loads of the connected equipment within
allowable values, Avoiding leakage at joints, Limiting sagging & displacement
within allowable values.)
C. Optimal Design (Avoiding excessive flexibility and also high loads on
supporting structures. Aim towards an optimal design for both piping and
structure.)
To meet these objectives several load cases are required during stress analysis. This
article will guide all the beginners with the methodology to build several load cases
which will be required for stress analysis.
In this article we will use following notations for building load cases:
WW=water filled weight of piping system,
HP=Hydrotest Pressure,
W=weight of pipe including content and insulation,
P1=Internal Design pressure,
T1=Operating temperature,
T2=Maximum temperature,
T3= Minimum temperature,
WIN1, WIN2, WIN3 AND WIN4: wind loads acting in some specific direction,
U1, U2, U3 AND U4: uniform (seismic) loads acting in some specific direction.
While analysis at a minimum the stress check is required for the below mentioned
cases:
a. Hydrotesting case: Pipelines are normally hydrotested before actual operation
to ensure absence of leakage. Water is used as the testing medium. So during this

situation pipe will be subjected to water weight and hydrotest pressure.

Accordingly our first load case in Caesar II will be as mentioned below
1.

WW+HP

HYD

b. Operating case: When operation starts working fluid will flow through the
piping at a temperature and pressure. So accordingly our operating load cases will
be as mentioned below:
2.
3.
4.

W+T1+P1
W+T2+P1
W+T3+P1

OPE
OPE
OPE

for operating temperature case

for maximum system temperature case
for minimum system temperature case

c. Sustained Case: Sustained loads will exist throughout the plant

operation. Weight and pressure are known as sustained loads. So our sustained
load case will be as follows:
5.

W+P1

SUS

d. Occasional Cases: Piping may be subjected to occassional wind and

seismic forces. So to check stresses in those situations we have to build the
following load cases:
6.
7.
8.
9.
10.
11.
12
13

W+T1+P1+WIN1
W+T1+P1+WIN2
W+T1+P1+WIN3
W+T1+P1+WIN4
W+T1+P1+U1
W+T1+P1-U1
W+T1+P1+U2
W+T1+P1-U2

OPE
OPE
OPE
OPE
OPE
OPE
OPE
OPE

Considering wind from +X direction

Considering wind from -X direction
Considering wind from +Z direction
Considering wind from -Z direction
Considering seismic from +X direction
Considering seismic from -X direction
Considering seismic from +Z direction
Considering seismic from -Z direction

While stress analysis the above load cases form load case 6 to load case 13 is
generated only to check loads at node points.
To find occasional stresses we need to add pure occassional cases with sustained
load and then compare with code allowable values. Following sets of load cases
are built for that purpose.
14.
L6-L2
OCC
Pure wind from +X direction
15.
L7-L2
OCC
Pure wind from -X direction
16.
L8-L2
OCC
Pure wind from +Z direction

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

L9-L2
L10-L2
L11-L2
L12-L2
L13-L2
L14+L5
L15+L5
L16+L5
L17+L5
L18+L5
L19+L5
L20+L5
L21+L5

OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC
OCC

Pure wind from -Z direction

Pure seismic from +X direction
Pure seismic from -X direction
Pure seismic from +Z direction
Pure seismic from -Z direction
Pure wind+Sustained
Pure wind+Sustained
Pure wind+Sustained
Pure wind+Sustained
Pure seismic+Sustained
Pure seismic+Sustained
Pure seismic+Sustained
Pure seismic+Sustained

Load cases from 22 to 29 will be used for checking occasional stresses with respect
to code B 31.3 allowable (=1.33 times Sh value from code). Use scalar
combination for load cases 22 to 29 above and algebraic combination for others as
shown in figure attached below:

e. Expansion Case: Following load

expansion stress range as per code

cases

are

required

for

checking

30.
31.
32.
33.

L3-L4

L2-L5
L3-L5
L4-L5
EXP

EXP
EXP
EXP
for complete stress range

The above load cases (from 30 to 33) are used to check expansion stress
The above mentioned load cases are minimum required load cases to analysis any
stress system. Out of the above load cases the load cases mentioned in point
number 1, 5, and 22-33 are used for stress check. And load cases mentioned in
point number 1 to 13 are used for checking restraint forces, displacements and
nozzle load checking.
Few additional load cases may be required for PSV connected systems, Rotary
equipment connected systems.
Seismic and Wind analysis may not be required every time. So those load cases can
be deleted if the piping system does not fall under the purview of seismic and wind
analysis by project specification. However to perform wind and seismic analysis
proper related data must have to be entered in Caesar II spreadsheet (Will be
discussed in my future posts).
If the stress system involves use of imposed displacements (D) and forces (F) then
those have to be added with the above load cases in the form of D1, D2 or F1, F2
as applicable.
It is a better practice to keep
1. Hydro and sustained stresses below 60% of code allowable
2. Expansion and occasional stresses below 80% of code allowable
3. Sustained sagging below 10 mm for process lines and below 3 mm for steam,
two phase and flare lines
4. Design/Maximum displacement below 75 mm for unit piping and below 200
mm in rack piping.