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Version 2019 (11.0)
April 2019
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Bends .......................................................................................................................................................... 78
Bend Definition ...................................................................................................................................... 78
Single and Double Flanged Bends or Stiffened Bends......................................................................... 79
180º Return Fitting-to-Fitting 90º Bends ............................................................................................... 80
Mitered Bends ....................................................................................................................................... 81
Closely-Spaced Mitered Bend ........................................................................................................ 82
Widely-Spaced Mitered Bend ......................................................................................................... 83
Elbows - Different Wall Thickness ........................................................................................................ 85
Bend Flexibility Factor ........................................................................................................................... 87
Restraints ................................................................................................................................................... 88
Anchors ................................................................................................................................................. 89
Anchors with Displacements .......................................................................................................... 90
Overview
Refer to this guide for tutorials of complete systems and examples of specific piping
components.
The sections below illustrate the techniques and methods used to model individual piping
components:.
• Bends (page 78)
• Restraints (page 88)
• Hangers (page 130)
• Expansion Joints (page 148)
Examples (page 173) illustrate the use of CAESAR II for different piping problems, seldom-used
components, or unusual geometries.
Tutorial A (page 9) and Tutorial B (page 48) show the modeling and analysis workflow of a
complete system. Work through these sections if you have not previously used CAESAR II.
The boundaries of the system are the pump discharge nozzle (on the right) and the vessel
nozzle (on the left). The pump nozzle is a satisfactory boundary because the movement of that
point (as the pump heats up in operation) is known and easily calculated from the thermal strain
between the pump nozzle and the base point. The vessel nozzle is an adequate boundary
because of the known thermal growth of the vessel and the greater stiffness of the vessel with
respect to the 8-inch pipe.
You can take an opposite approach by modeling the pipe ends to immovable points, such as
the vessel foundation and the pump support (or base) point.
When you require a more accurate model for supporting structures, you can include
structural steel in the model.
The check valve sits on top of the welding tee for the 6-inch bypass piping. The 6-inch line runs
through a gate valve before reentering the 8-inch line through a second welding tee above the
check valve. The total weight and length of this valve assembly is unknown. Because of this, the
valve lengths and weights are pulled from the CAESAR II generic database.
The spring hanger above this valve assembly carries the deadweight and absorbs the thermal
growth of the vertical pipe run. The hanger attaches to the elbow in line with the vertical pipe at
the near end of the elbow. The hanger is quite sensitive to the weights used. The difference
between the actual installed valve weights and modeled weights should be used to adjust the
spring preload. In Tutorial B you will verify that the hot load on the spring is toward the center of
the manufacturer's recommended spring working range to allow errors in load estimation. An
appreciable change in these weights requires reanalysis of the system.
The weld point on the vertical run of the elbow is the near end and the horizontal run weld
point is the far end.
The other end of the hanger attaches to available structure above the model. Because of the
vertical thermal growth of the hanger attachment point, you cannot use a simple rod hanger.
The horizontal piping rests on an unspecified support at the far end of the next elbow. This
support, modeled as a rigid nonlinear restraint acting on the pipe centerline, allows the
piping to move upward but prevents downward motion.
1. In the main CAESAR II window ribbon, click Home > Setup > Configure .
The CAESAR II Configuration Editor displays.
2. Set the numeric increment between nodes, using an increment of 5 between node numbers.
The default increment is 10, so you must change it.
Click the Geometry Directives category, and then select 5 in the Auto Node Number
Increment list.
1. In the main window ribbon, click Home > Input > Piping Input .
Because this is a new job, the Review Current Units dialog box again displays. Click OK to
close it. A new window with command toolbars, the Classic Piping Input dialog box, and a
graphic view displays.
CAESAR II automatically generates the From and To nodes when you start a new piping
element. The From box displays 5 and the To box displays 10 because you set the node
increment to 5 in the CAESAR II Configuration Editor dialog box. The default -Mill Tol %
value for the piping code also displays.
The graphics view displays and updates your piping system as you define element
properties.
3. In the Diameter box, type 8 to specify the nominal pipe size of 8 in.
The software replaces the nominal value with the actual outer diameter (OD) of 8.6250 in.
The pipe element updates in the graphic view.
6. In the Fluid Density box, type 0.8SG to specify the specific gravity of 80 percent of the
deadweight of water.
The software replaces the specific gravity with the fluid density of 0.02889 lb./cu.in.
7. In the Material list, select (1)LOW CARBON as the pipe material.
The software queries the material database and adds values for Elastic Modulus,
Poisson’s Ratio, and Pipe Den. The software also references the material number to add
the coefficient of expansion for the specified temperatures.
8. In the Insul Thk box, type 3 to specify the insulation thickness in inches. In the Insulation
Density list, select Calcium Silicate.
The software replaces the insulation material type with the insulation density of 0.00666
lb./cu.in.
Optionally, type 11.5/1728 in the Insulation Density box. 11.5 is the density in
lb./cu.ft. 1728 is the factor (123) to convert the density to lb./cu.in. Numeric fields allow
simple math.
9. Double-click the Displacements check box to display the Displacement tab on the right.
5 displays as the value for Node 1.
10. Define displacements for the thermal growth of the pump discharge nozzle from the base
support (anchor) point. For anchor displacement DY in the Vector 1 column, type 0.077. For
anchor displacement DZ in the Vector 1 column, type 0.046.
The displacement vector displays in the graphic view.
11. Type 0 for the other four degrees of freedom (DX, RX, RY, and RZ).
If you do not assign values for DX, RX, RY, and RZ, then node 5 is free to move
in these directions.
12. Double-click the Allowable Stress check box to display the Allowable Stress tab on the
right.
13. In the Code list, select B31.3 if it is not the default selection.
14. Type the following values:
If a job is new, CAESAR II first opens the Review Current Units dialog box. For an existing
job, the Classic Piping Input dialog box opens directly with the first piping element active.
If the Units File Label box on the Review Current Units dialog box does not show Imperial
units, click Cancel, and then select Tools > Configure Setup. Click the Database
Definitions category and select English in the Units File Name list.
1. Double-click the SIFs & Tees check box to display the SIFs/Tees tab on the right.
2. In the Node box, specify 10 as the intersection node.
3. In the Type list, select 3 - Welding.
CAESAR II calculates the SIFs at this intersection according to the selected B31.3 piping
code.
1. Click Continue on the Navigation Tools toolbar to define the next length of pipe.
You can also press ALT-C or click Edit > Continue.
The To node 10 of the previous element now displays as the From node. The To node is
15. All pipe material properties carry forward from the previous element. Allowable stress
data also carries forward, even though the Allowable Stress box is cleared.
2. In the DY box, type 7 to specify the element length of 7 in. Press TAB.
Do not select Allowable Stress unless you have a change in material, code, or
temperature.
Uniform Loads and Wind also carry forward without selecting the check box. No other
component information, boundary conditions, or loading conditions carry forward.
2. Click Model > Valve, or click Valve/Flange Database on the Input Tools toolbar.
The Valve and Flange Database dialog box displays.
3. Select CHECK from the Rigid Type list and FLG from the End Type list. Click OK.
A 150 psi class flanged check valve displays between nodes 15 and 20.
The software adds valve data to the Classic Piping Input dialog box. The element length
DY is 2 ft. 3.75 in., Rigid is selected, and the weight of the valve and flanges of 470.000
displays in the Rigids tab.
If you know the length and weight of the valve, you can directly specify the DY length and
the Rigid Weight in the Rigids tab.
If the Valve and Flange Database dialog box does not display, see Configuration Editor in
the CAESAR II User's Guide.
1. Double-click the SIFs & Tees check box to display the SIFs/Tees tab on the right.
2. In the Node box, specify 25 as the intersection node.
3. In the Type list, select 3 - Welding.
CAESAR II calculates the SIFs at this intersection according to the selected B31.3 piping
code.
2. In the DY box, type 10- 2 to specify the element length of 10 ft. 2 in. Press TAB.
1. Double-click the Bend check box to display the Bends tab on the right.
The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node 28
at the elbow near point (Angle 2 of 0.000), and node 29 at the midpoint (Angle 1 of M).
Node 30 moves to the elbow far point.
The elbow is part of the vertical pipe run, but does not display until you create the
horizontal pipe run.
2. Double-click the Hangers check box to display the Hangers tab on the right.
3. Type 28 in the Node box to place the hanger at the elbow near point.
4. Clear the Allow Short Range Springs box. Use the default value of 1 - ANVIL for Hanger
Table.
1. Double-click the Bend check box to display the Bends tab on the right.
The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node 33
at the elbow near point (Angle 2 of 0.000), and node 34 at the midpoint (Angle 1 of M).
Node 35 moves to the elbow far point.
.
Similar to the first elbow, the elbow is part of the horizontal pipe run, but does not
display until you create the next pipe element.
2. Double-click the Restraints box to display the Restraints tab on the right.
3. Type +Y in the Type box to place the support at the elbow far point.
With no stiffness specified with the restraint, CAESAR II sets the restraint as very stiff (rigid).
This means that under any practical load, the pipe does not push the restraint downward.
The restraint displays as a vector.
3. Double-click the Displacements check box to display the Displacement tab on the right.
40 displays as the value for Node 1.
4. Define displacements for the thermal growth of the pump discharge nozzle from the base
support (anchor) point. For anchor displacement DY in the Vector 1 column, type 0.077. For
anchor displacement DZ in the Vector 1 column, type 0.046.
5. Define displacements for the thermal growth of the vessel nozzle. In the Vector 1 column,
type the following values:
DX 0.0
DY 0.28
DZ -0.1
The software replaces S with the actual wall thickness of 0.2800 in.
1. Double-click the Bend check box to display the Bends tab on the right.
The software creates a long radius elbow (1-1/2 times the nominal pipe diameter) for the
6-inch line, node 603 at the elbow near point (Angle 2 of 0.000), and node 604 at the
midpoint (Angle 1 of M). Node 605 moves to the elbow far point.
2. In the Type list, select 1 -Single Flange.
Similar to the previous elbows, the elbow does not display until you create the
next pipe element.
Each elbow on the bypass is flanged on the end closest to the gate valve. The flange acts
like a stiffening ring, reducing the bending flexibility of the elbow. This characteristic of flanged
elbows is addressed by the piping codes through a modification of the flexibility factor and stress
intensification for the elbow.
You can change the default 1percent attachment length by specifying a new value for Bend
Length Attachment Percent in Tools > Configure/Setup .
The software adds valve data to the Classic Piping Input dialog box. The element length
DY is 1 ft. 5.750 in., Rigid is selected, and the weight of the valve and flanges of 225.000
displays in the Rigids tab. The software includes these values in the analysis.
Select NOFLG in the End Type list of the Valve and Flange Database dialog box if you do
not want to include the deadweight and length of the attached flanges in the analysis.
5. Double-click the Bend check box to display the Bends tab on the right.
The software creates a long radius elbow (1-1/2 times the nominal pipe diameter) for the
6-inch line, node 618 at the elbow near point (Angle 2 of 0.000), and node 619 at the
midpoint (Angle 1 of M). Node 620 moves to the elbow far point.
6. In the Type list, select 1 -Single Flange.
Similar to the previous elbows, the elbow does not display until you create the
next pipe element.
Review Graphically
You built your model using the default piping input layout, with a graphic view displaying to the
right of the Classic Piping Input dialog box. The size of the graphic view can be increased by
clicking Auto Hide in the upper right corner of the Classic Piping Input.
To display the node numbers, click Node Numbers on the Plot Tools toolbar, or press N.
Click Orbit on the Standard Operators toolbar, and then use the arrow keys to rotate the
plot. You can also use the arrow keys or mouse to pan the plot after clicking Pan . Scrolling
the mouse zooms the model and pressing the center mouse button pans the plot. Clicking the
right mouse button, and then clicking Operators > Pan from the pop-up menu provides an
alternative method of panning the plot. The model then follows the cursor. The plus sign (+)
zooms in and the minus sign (-) zooms out. There are toolbar buttons and menu items to alter
the pan view and to display element and restraint information on the plot. Use these different
items to become familiar with them. To reset the plot to the default, click Reset on the Reset
toolbar or click View > Reset. To print a copy of the display, click File > Print or click Print
on the Standard toolbar.
Because the graphics are included in the input processor, the graphic must be clicked
to set the focus before printing.
The V key toggles different views. The volume plot shown below is especially useful for larger
models because it uses less of the computer's resources.
The illustration below shows a view down the Z-axis with a zoom and pan to show the pipe
valves. This volume plot shows the nodes and identifies the tees. To see the displacements
specified in the model, click Displacements or Options > Displacements.
1. Click Edit Static Load Cases on the CAESAR II Tools toolbar, or click Edit > Edit
Static Load Cases.
The Static Analysis - Load Case Editor dialog box displays.
CAESAR II begins with a standard set of load cases based upon the piping code selected
and the loads defined in input. For this tutorial, the software includes load cases to size the
hanger before performing the standard structural and stress analyses. The hanger sizing
algorithm requires two analyses before analyzing the standard load cases:
The operating condition for this analysis consists of the dead weight of the pipe, its contents and
insulation, the design temperature and pressure, and the preload on the hanger at node 28. The
installed condition includes the dead weight and hanger preload. In addition to these structural
analyses, certain stress conditions must be addressed.
For the piping code, the sustained and expansion stresses must be calculated. Sustained
stresses include dead weight, preloads, and pressure. Sustained stresses can be taken from the
installed condition analysis if the pressure loads are included. CAESAR II includes the pressure
term in the installed case because pressure, in most cases, has no impact on the structural
loads on the piping. With the installed case structural analysis also serving as the sustained
case stress analysis, no additional load case must be added to calculate the sustained stresses.
Expansion stresses reflect the change in system position from its installed position to its
operating position. Because of system non-linearity, this change in position cannot be
determined by analyzing thermal loads alone.
By default, CAESAR II constructs a third load case to calculate the expansion stress (range).
This case is not a third, complete analysis of the system. Instead, it is a product of the operating
and installed structural analyses already performed. The difference in system displacements
between these two cases is the displacements stress range from which the expansion stresses
are calculated. The third class of stress in piping – occasional stresses (as opposed to
expansion and sustained) – is not included in the recommended analyses and must be specified
by you. Likewise, Fatigue (FAT) stress cases are provided only when specifically required by the
active piping code (TD/12, for example).
For most systems, the recommended load cases are exactly what you want to analyze.
L1 (W) - Weight for hanger loads
Calculates the dead weight carried by the proposed spring at node 28.
L2 (W+D1+T1+P1) - Operating for hanger travel
Calculates the vertical travel of the proposed spring. All load categories, which compose the
operating load case, are used for this analysis. These are dead weight, displacements,
thermal set 1, and pressure set 1. With these two numbers—the load carried by the hanger
and the amount of travel it must accommodate—The software selects the appropriate spring
from the Anvil catalog. This spring and its proper preload are installed in the model for the
remaining analyses.
L3 (W+D1+T1+P1+H) - Operating case condition 1
Defines the operating hanger load case. L3 is identical to L2 but includes the sized hanger
preload (H). This analysis produces the operating forces and moments on the supports, and
the deflections of all points in the system. L3 is a structural analysis case and not a B31.3
stress analysis case. The refining piping code does not recognize pipe stress in the
operating condition as a test for system failure and does not establish a limit for this state of
stress.
L4 (W+P1+H) Alternate sustained stress based on operating condition 1
Provides an alternate method for the sustained case of L5, using the restraint status from
the L3 operating load case to evaluate the stresses induced by primary loads.
L5 (W+P1+H) - Sustained case condition 1
Defines a structural and stress case of a cold system. The load case eliminates the
(assumed) thermal effects (D1+T1). By including pressure (P1), this case also has the
necessary components to be used to report the system’s sustained stresses.
L6 (L3-L5) - Expansion case condition 1
Defines an algebraic combination of two basic load cases. The displacements of L5 are
subtracted from the displacements of L3 to produce these results. This case develops the
displacement range of the system in its growth from the installed position to the operating
position. This displacement range is used for the calculation of the system’s expansion
stresses.
All the results are automatically into the Tutor._p statics output file. The contents of a ._p file
can only be examined through the Static Output Processor.
If you want to review analysis results at a later time, you do not need to rerun the static
analysis . Click Output > Reports > Static from the ribbon on the main window to
display the output.
Output > Reports > Static from the main CAESAR II window.
With the first run of static analysis, you are typically verifying that the piping model is responding
as expected. Checking deflections and restraint loads in the operating and installed cases
should quickly uncover any major problems with the system layout or input. If the output verifies
the model, the results can be used to collect pipe stresses, support and equipment loads, and
any other useful data found in the output. This information is useful in documenting a good
piping design or troubleshooting an inadequate one. If there are unusual results, you will then
reexamine the input.
You can use commands on the Plot Tools toolbar to control display options, such
as supports, displacements, and node numbers.
2. Click Deflected Shape or Show > Displacement > Deflected Shape. The plot shows
the centerline plot along with a normalized deflected shape of the system in the operating
condition.
7. Press ENTER to display the stresses one at a time starting with the highest.
9. Return to the Static Output Processor by clicking Window > 1 <file name>.
Use the output wizard to create a book of reports in a specific order and then send them to
an output device. Click More>> in the Static Output Processor to access the wizard. Start
the report with the hanger table by selecting it and clicking [Add].
7. Select the operating and sustained load cases and displacements and restraint summary
reports.
8. Click Add again.
9. Add the sustained and expansion stress reports by having only SUS and OPE load cases
and Stresses highlighted.
10. Click Add again.
This completes a typical output report after reviewing the reports order.
11. Select the output device, and then click Generate TOC, if needed.
12. Click Finish.
A tabbed window with all reports displays.
Hanger report
Displacements reports
The deflections of nodes 5 and 40 were entered as input. Node 28 again moves up 0.750 in. in
the Y direction with the spring installed.
Look at the zero position of nodes 5 and 40. When the imposed displacements are not included
in the analysis, the node is fixed with zero movement in each of the defined directions.
Restraint summary
The restraint report lists the piping forces and moments on the restraint. It does not list the
restraint loads on the piping. The loads at node 5 are the nozzle loads and can be used without
sign change to check the API 610 allowable loads. Loads for node 40 can be used to check the
vessel stresses due to the nozzle loads.
The loads at 28 show the operating load and the actual installation load (with contents) for the
selected spring. The spring carries the designed load of 1209 pounds in the operation condition.
The +Y restraint at node 35 shows it is nonlinear nature. In the cold condition, the restraint is
active. As the piping moves to the hot position, it disengages from the support. Refer back to the
displacement reports to confirm that the Y displacement is 0.0 in the installed (sustained)
condition and +Y in the operating condition.
The summary shows that the sustained stresses throughout the system are below their
allowable values. The sustained stress closest to its allowable limit is at the vessel node 40.
Stress reports
The summary shows that the expansion stresses throughout the system are below their
allowable values. The expansion stress closest to its allowable limit occurs along the header at
the node 10 tee.
For the stress detail report, note the application of the tee and bend stress intensification factors.
The tee at 25 has SIFs other than 1.00 for all three listings: 25 to 28, 20 to 25, and 25 to 620.
Bend SIFs are applied only on the bend side of the node compare node 28 on 25-28 and 28-29.
No stresses are listed for rigid elements as no valid moment of inertia is provided for these
elements.
Conclusions
The review of piping stresses shows that the piping has adequate wall thickness and support to
keep within the sustained allowable stress, as well as enough flexibility to remain below the
expansion allowable stress limit. A quick review of the system displacements does not reveal
any interference problems from pipe expansion.
Equipment loads
Equipment loads must still be checked to ensure a safe and effective design. The pump loads at
node 5 may be compared to the API (American Petroleum Institute) Standard 610 (Seventh
Edition, February 1989), Centrifugal Pumps for General Refinery Service. The nozzle loads, too,
can be compared to the allowed maximum limits. The nozzle loads can be translated into local
stresses using Welding Research Council Bulletins 107 or 297 - Local Stresses in Cylindrical
Shells Due to External Loadings on Nozzles (WRC 107) or it's Supplement (WRC 297). These
local stresses can then be compared to allowable stress values established in ASME Section
VIII Division 2 Appendix 4, Mandatory Design Based on Stress Analysis.
Because the loads on these boundary conditions are related to the piping system layout, the
piping system cannot be properly approved until these load limits are also verified. These
verifications are performed in Tutorial B - Check equipment and redesign a piping system (page
48).
Archiving
Final reports should now be made to document this design. The input listing can be generated
from Classic Piping Input or from the Static Output Processor. You should include the
current status of the software’s default settings in this input echo and a hard-copy of a few input
plots. Structural and stress results from the Static Output Processor substantiate the current
design.
Archive the files Tutor-A.C2 and Caesar.cfg to preserve a copy of the CAESAR II input, load
case definition, output, and software default settings. Often upon release of a new version of
CAESAR II, archived files must be converted to the new version and subsequently re-analyzed.
This is primarily due to changes within CAESAR II as new features and codes are added. To
avoid this, keep the old version of the software available, and use newest version for new
analyses.
For an analysis of a production system, you typically want both suction and discharge
loads.
Even though all loads are not known, you will provide the entire description of the pump for
Equipment Analysis. The following graphic illustrates the orientation of this pump with its end
suction nozzle and top discharge nozzle. Both nozzles are dimensioned back to the base point,
which is the intersection of the shaft axis and the support line for the pump. The drive shaft
centerline is along the local X-axis of the pump.
Refer to the static analysis output from Tutorial A to get the discharge nozzle loads. Because the
discharge nozzle served as a boundary condition for this analysis, the restraint reports list the
nozzle loads. The forces and moments on the restraint at node 5 represent the piping loads
acting on the discharge nozzle. The operating loads and installation loads must both fall below
the defined limits. Examination of the restraint summary for the operating and sustained
(installed) cases reveals that the operating loads are the controlling case to use for the
discharge nozzle analysis.
Perform analysis on the pump using the discharge loads from the piping analysis
1. In the main window ribbon, click Analysis > Components/Equipment > Equipment
Analysis .
The Equipment Analysis dialog box displays.
2. Select API-610 in the Equipment pane on the left, and then click Add .
Pump1, with a default Suction nozzle, Discharge nozzle, and Load Case
Sets, displays in the Equipment pane.
3. Select Pump1 in the Equipment pane, and specify the following properties on the
Pump Input tab:
Equipment Name: Bottoms Pump
Description - Tutorial B. Check discharge nozzle.
Allowable Load Multiplier: 1.00
Centerline Direction Cosine X: 1.00
4. Select Suction in the Equipment pane, and specify the following properties on the
Nozzle Input tab:
Orientation: End
Nominal Diameter: 10 in. (250 mm)
Location from Pump Center, DX (in.): 15.00
CAESAR II Node Number: 105
For this tutorial, the node number is arbitrary and does not exist in the model.
In a production analysis, the node number identifies a node containing suction nozzle
loads from the static analysis.
CAESAR II Output File - C:\ProgramData\Intergraph CAS\CAESAR
II\11.00\Examples\Tutor-B
5. Select Discharge in the Equipment pane, and specify the following properties on the
Nozzle Input tab:
Orientation: Top
Nominal Diameter: 8 in. (200 mm)
Location from Pump Center, DY (in.): 20.00
Location from Pump Center, DZ (in.): 12.00
CAESAR II Node Number: 5
This node number corresponds with the first node in the model, which defines
the discharge nozzle boundary condition in the model.
CAESAR II Output File: C:\ProgramData\Intergraph CAS\CAESAR
II\11.00\Examples\Tutor-B
9. For the Load Cases: Bottoms Pump - Suction grid at the top of the Load Case Sets tab,
click Add Case > Add Custom.
A load case numbered 1u displays.
Because the suction nozzle has no loads for this model, leave the force and
moment values at 0.
10. Create two load case sets:
Select the suction load case and the OPE discharge load case. For the Load Case
Sets grid at the bottom of the Load Case Sets tab, click Create a Set from Selected
Load Cases .
Select the suction load case and the SUS discharge load case. Click Create a Set from
Selected Load Cases .
Two load case sets display.
15. Click Print to print the report, or click Export to save the report in Excel, Word, or
PDF format.
Page 3 of the report shows that the analysis exceeds API Table 5 limits for the operating
load case.
When the nozzle load components are greater than the Table 5 values but less than
two times the Table 5 values, the pump might still pass (when permitted by purchaser
specifications) if other checks are within their allowable values. However, this evaluation cannot
be used because loading on the suction nozzle is unknown.
Piping loads on the pump discharge nozzle exceed API 610 allowable stresses.
The plot shows that the large moment about the Z-axis at the pump is caused by the thermal
growth of B working against the stiffness of legs A and C. The large moment about the X-axis is
due to the thermal growth of A working against the stiffness of legs B and C. The thermal growth
of the steam stripper vessel connection (at the left end of A and node 40 in the piping system
model) may also contribute to these high loads.
How can excessive loads at the pump discharge nozzle be reduced? How can additional
flexibility be added to the system so that these loads drop? The possible solutions are:
Incorporate flexibilities at the vessel/nozzle intersection.
Redesign the piping system to reduce stiffness by adding an expansion loop or an
expansion joint to the piping.
T = vessel thickness (3/16 in wall thickness + 1/4 in. reinforcing pad = 7/16 in.)
Because the vessel is vertical and the nozzle is in the Z direction, the software defines
flexibilities at node 40 for translation along the Z-axis and rotation about the X- and Y-axes. The
other three degrees-of-freedom (the three local shear terms) remain rigid because the nozzle
was modeled as a rigid connection with its thermal deflections.
1. In the main window ribbon, click Home > Input > Piping Input with Tutor-B as the
current model file.
The Classic Piping Input dialog box and a graphic view display.
2. Click File > Save As, and change the model file name to Tutor-B2.
3. Click Next Element repeatedly to advance through the model, or double click the
graphic view at the end of the horizontal run to display element 35-40.
4. Click the Displacements box.
The Displacements tab of the auxiliary panel displays.
5. Change the value of Node 1 from 40 to 6000. Do not change the displacement values.
Node 6000 represents the steam stripper vessel. Because the vessel has thermal
growth, the thermal displacements previously assigned to node 40 are reassigned to the
new vessel node 6000. Do not define a piping element between nodes 40 and 6000.
6. Double-click the Nozzle Flex box.
The Nozzles tab displays on the right.
7. Specify the following properties on the Nozzles tab:
Nozzle Type: WRC 297
Nozzle Node: 40
Vessel Node (optional): 6000
Direction Cosines: VY: 1
A value of 1 for the Y-direction vector specifies a vertical vessel.
Nozzle Details:
Outer Diameter: 8.625
Wall Thickness: 0.322
Distance to Stiffener or Head: 48.000
Distance to Opposite Stiffener: 72.000
Vessel Details:
Outer Diameter: 60.000
Wall Thickness: 0.250
Pad Thickness: 0.188
With the addition of these properties, the software applies the calculated nozzle
flexibilities between nodes 40 and 6000.
For WRC 297, the nozzle and vessel orientation defines the local coordinate system.
With the nozzle in the Z-direction and the vessel in the Y-direction, the new axial
stiffness is in the global Z-direction (the nozzle centerline), longitudinal bending is about
the global X-axis (bending into the vessel centerline or long axis), and circumferential
bending is about the global Y-axis (about the vessel centerline).
Because WRC 297 flexibilities are sensitive to the proximity of stiffeners to the nozzle,
the software specifies the vessel dimensions. A tray in the vessel is closest to the
nozzle and 4 feet above the nozzle. On the other side of the nozzle, the bottom head
tangent and skirt connection is 6 feet below.
8. Click Save to save definition of the WRC 297 vessel nozzle.
Check the sustained and expansion stresses to confirm that they are still below their
allowable limits
The highest sustained (SUS) stress is 1282 psi. This is below the allowable limit.
Similarly, the highest expansion (EXP) stress is 14,103 psi (not shown). This is also below the
allowable limit.
The software selected a lighter size 9 spring for installation at node 28 for a 904 lb. hot load. For
the original analysis, the software selected a size 10 spring for a 1209 lb. hot load. The weight of
the piping system did not change, but the new analysis has a reduced longitudinal bending
stiffness at the nozzle.
its installed position, but lifted off the support as it went into operation. The hanger sizing
algorithm re-adjusted the spring load so that the spring carries its portion of the system, with
the system no longer resting at 35. In this second analysis, the restraint at 35 remains active
in the operating position, therefore the hanger at 28 does not carry any additional load from
35. The added longitudinal bending flexibility at node 40 allows the pipe to rest at node 35.
For the vessel nozzle at support 40:
The support definition at node 40 shows the changes inherent in the WRC 297 nozzle
flexibility calculations. Flexibilities are added in the axial and bending directions (Z, RX, and
RY), while the shear terms (X, Y, and RZ) remain rigid. This added flexibility greatly reduces
the bending moments about the X- and Y-axes at node 40.
The reduced loads result from modeling refinements, not design modifications. If the vessel
nozzle connection meets the requirements of WRC 297, you can gain much from nozzle
flexibility.
Show the displaced position of the piping system in its operating condition
The imposed thermal growth of the nozzle (in the original analysis) was removed from node 40
and redefined at node 6000. When you compare displacements at node 6000 and node 40, you
can see the impact of the nozzle flexibilities. Circumferential bending flexibility (RY) and
longitudinal bending flexibility (RX) play a large role in the weight distribution of the system.
You now must reanalyze the pump discharge nozzle loads to see if they meet the allowable
limits of API 610.
Analysis .
The Equipment Analysis dialog box displays, containing values from the initial analysis.
5. Click Analyze .
As the analysis runs, the software places messages in the Event Log. A report displays on
the Output tab when analysis completes.
6. On the Output tab, click Next Page to advance to new pages.
The report displays analysis results on the discharge nozzle for the OPE and SUS load
cases.
7. Click Save .
Page 3 of the report shows that while results are improved, the analysis still exceeds API Table
5 limits for the operating load case.
The report shows that the Y-moment on the discharge nozzle is well below the limit. The
X-moment remains more than twice the allowable load. The Z-moment also exceeds the
allowable.
Exceeding twice the allowable load would be fine if Condition F.1.2.b is satisfied, but it is not, as
shown on page 5 of the report.
The sum of the ratios is 2.82, which does not meet condition F.1.2.b, which states that the
combined force/moment load ratios must be less than 2.0. The pump loads are still too high.
The spring support in the model might prove the pump loads can be brought within
their allowable values. As discussed in Review static output reports for the new analysis (page
59), the spring at node 28 directly controls the vertical load on the discharge nozzle. This spring
pre-load could be ideally set so that when the pump is in operation, there is no pump load in the
Y-direction. For the current analysis, the hanger carries 904 lb. in the operating position while
the pump carries 1809 lb. If the spring load carried 2713 lb., the load on the pump would be zero
(0) in Y.
For a quick check, you can manually set the Y-load to 0, and then reanalyze the pump in
Equipment Analysis. The results show Condition F.1.2.b reduced to 2.33, which remains
above the allowable load limits.
Pump loads are still above allowables, and a redesign of the system is needed.
The best location for an expansion loop is determined by the orientation of leg A, which creates
the excessive thermal strain. The added piping to generate the expansion loop lies
perpendicular to leg A. For this system, pipe can be added in either the X- or Y-direction. This
added pipe effectively increases the cantilever length which is displaced by leg A. By increasing
the cantilever length, the stiffness is reduced and loads drop.
There are several conditions which set the loop size:
Available support location
Maximum distance between supports
Cost of pipe
Available space
For this tutorial, you will add an eight-foot by eight-foot loop of pipe and an additional support on
leg A in the X-direction. For systems that are not analyzed, the recommended maximum
spacing between supports for 8-inch water-filled pipe is 19 feet (see ASME B31.1 121.5 or MSS
SP-69). The 8-foot loop run lengthens the 30 - 35 pipe from 12 feet to 20 feet, which is close to
the recommended spacing.
1. Return to the main window ribbon, and click Home > Input > Piping Input with
Tutor-B2 as the current model file.
The Classic Piping Input dialog box and a graphic view display.
2. Click File > Save As, and give the model file a new name of Tutor-B3.
3. Click Next Element repeatedly to advance through the model to display element 30-35.
You can also click on element 30-35 or use Find Node to go directly to the
element.
4. In the DX box, type -20- to change the element length from 12 ft. to 20 ft. Press TAB.
5. Click the Restraints box to display the Restraints tab on the right.
6. For the +Y restraint, change Node from 35 (the node at the end of the elbow) to 33 (the
node at the beginning of the elbow).
8. Break element 30 - 35 by adding node 32 at the 10 ft. (10-) midpoint, and then click OK.
The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node 133
at the elbow near point (Angle 2 of 0.000), and node 134 at the midpoint (Angle 1 of M).
Node 135 moves to the elbow far point.
The elbow is part of the horizontal pipe run, but does not display until you create
the horizontal pipe run.
Add an elbow and adjust the From node for the final element
1. Double-click the Bend check box to add the bend at node 235.
The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node 233
at the elbow near point (Angle 2 of 0.000), and node 234 at the midpoint (Angle 1 of M).
Node 235 moves to the elbow far point.
Again, the elbow is part of the horizontal pipe run, but does not display until you
create the horizontal pipe run.
2. Click Next Element to advance to element 135 - 40.
3. In the From node box, type the value of the new node, 235, and then press TAB.
The software attaches the new loop to the last element of the pipe.
3. Insert the restraint by adding node 140 at 5 ft. (5-) from node 135. In Copy Restraint from
Node, use the same +Y support as used at node 33 to create a new support with the same
properties at node 140.
The software breaks the element and inserts the new restraint.
The software disconnects the vertical Y restraint at node 5 while it calculates the dead
weight load carried by the proposed spring at 28, allowing the spring to carry the full vertical
load.
4. To save the model, click Save or File > Save.
5. As a final check, click Distance . Select Between Element Nodes, type 5 (the first
element) and 40 (the last element) in the boxes, and then click Calculate. In Results, the
length should be 26' 8 3/8", the same distance you measured in Tutorial A.
operating condition.
For this exercise, the loading on the suction side of the pump is assumed to meet
allowable loading. Two times the API allowable loading was used.
Because all six components of the discharge nozzle loads are below their limits, no additional
checks (conditions F.1.2.b. and F.1.2.c.) need to be made. The discharge nozzle is no longer
overloaded. The final pump evaluation cannot be made until the suction nozzle loads are
compared with their API 610 limits.
Conclusions
Piping stresses show that the pump discharge loads are now within their allowable limits.
Vessel loads
While not part of this tutorial, the vessel loads from the nozzle at node 40 should also be
checked. Unlike loads on the pump, these loads cannot be compared to a fixed load limit.
Instead, these loads must be converted to local stresses on the vessel and then compared with
the limits defined by ASME Section VIII, Division 2. As a very rough guide for evaluating local
vessel stresses, you can check the code defined stress on the pipe connected to the vessel. If
those stresses are below about 6000 psi, the vessel stresses should be adequate. Looking at
the operating, sustained, and expansion stresses at node 40, the maximum stress is less than
2500 psi. The vessel loads seem fine.
To check the stresses in detail, the Welding Research Council Bulletin 107 (WRC 107) can be
used to convert the applied forces and moments to the appropriate local stresses. CAESAR II
provides a processor to convert these loads into WRC 107 stresses and a second processor to
combine the different stress categories (general or local primary membrane stress intensity,
primary membrane plus primary bending stress intensity, and primary plus secondary stress
intensity) for comparison with their design limits.
Archiving
Final reports should now be made to document this design change. The input listing can be
generated from Classic Piping Input or from the Static Output Processor. You should include
the software's current default settings in this input echo and a hard-copy of a few input plots.
Structural and stress results from the Static Output Processor substantiate the current design.
Archive the files Tutor-B3.C2 and Caesar.cfg to preserve a copy of the CAESAR II input, load
case definition, output, and software default settings. Often upon release of a new version of
CAESAR II, archived files must be converted to the new version and subsequently reanalyzed.
This is primarily due to changes within CAESAR II as new features and codes are added. To
avoid this, keep the old version of the software available to view existing analyses, and use the
newest version for new analyses.
Bends
This section provides guidelines and recommended best practices for the modeling various
bend geometries in CAESAR II.
For detailed information about using the software to define bend geometry, see
"Component Information" in the CAESAR II User's Guide.
Bend Definition
A bend is defined by the element entering the bend and the element leaving the bend. The bend
curvature is always physically at the To end of the element entering the bend.
The input for the element leaving the bend must follow the element entering the bend. The bend
angle is defined by these two elements. The default bend radius is 1-1/2 times the pipe nominal
diameter (long radius), but it can be changed to any other value. When you specify a bend, two
additional intermediate nodes are automatically generated--one at the 0º location and one at the
bend midpoint (M).
For stress and displacement output, the To node of the element entering the bend is located
geometrically at the far-point on the bend. The far-point is at the weld line of the bend, adjacent
to the straight element leaving the bend. The 0º point on the bend is at the weld line of the
bend, adjacent to the straight element entering the bend.
The From point on the element is located at the 0º point of the bend (and no 0º node point is
generated) if the total length of the element as specified by DX, DY, and DZ is equal to:
R tan (b / 2)
Where b is the bend angle, and R is the bend radius of curvature to the bend centerline.
Nodes defined by the Angle and Node properties are placed at the given angle on the bend
curvature. The angle starts with zero degrees at the near-point on the bend and goes to b
degrees at the far-point of the bend. Angles are always entered in degrees. Entering the letter M
as the angle designates the bend midpoint.
Nodes on the bend curvature cannot be placed closer together than the angle distance specified
by Minimum Angle to Adjacent Bend in the Geometry category of the Tools >
Configure/Setup command. This includes the spacing between the nodes on the bend
curvature and the near- and far-points of the bend.
The minimum and maximum total bend angle is specified by the Minimum Allowable Bend
Angle and Maximum Allowable Bend Angle properties, also in the Geometry category of the
Tools > Configure Setup command.
180º Bend:
DX = 2R
Mitered Bends
Evenly spaced mitered bends, whether closely or widely spaced, are defined by two parameters:
The number of cuts (changes in direction)
The equivalent radius or miter spacing
For closely spaced miters, the equivalent radius is equal to the code defined as R1 for B31.3
and R for B31.1. The equation for the equivalent radius to the spacing for evenly spaced miters
is:
Req = S / [ 2 tan(θ) ]
Where:
Where:
N = number of cuts
When using B31.1, an additional parameter, B (length of miter segment at crotch), is examined
for closely spaced miters. The following equation is used to compute B for evenly spaced miters:
B = S [ 1 - ro / Req ]
Where:
θ = α / 2N
= 90 / [2(4)]
= 11.25º
= 40
Calculate the ∆ coordinates to get from the tangent intersection point of the single cut miter bend
at node 10 to the single cut miter bend at node 15.
The straight pipe section coming into and going out of the bend must be ≥ Reqsin (θ).
Enter widely spaced miters as individual straight pipe elements, with bends specified,
having one miter cut.
Thick Elbow:
Restraints
This chapter provides guidelines and recommended best practices for modeling various types of
restraints in CAESAR II.
In This Section
Anchors .......................................................................................... 89
Flexible Nozzle - WRC Bulletin 297 ............................................... 92
Double-Acting Restraints ............................................................... 99
Single-Directional Restraints ......................................................... 100
Guides ............................................................................................ 101
Limit Stops ..................................................................................... 103
Windows ........................................................................................ 105
Rotational Directional Restraints with Gaps .................................. 106
Single-Directional Restraint with Predefined Displacement .......... 107
Single-Directional Restraint and Guide with Gap and Predefined
Displacement ................................................................................. 108
Restraint Settlement ...................................................................... 109
Skewed Double-Acting Restraint with Gap .................................... 110
Skewed Single-Directional Restraint ............................................. 111
Restraint between Two Pipes Using CNodes................................ 112
Restraint between Vessel and Pipe Models .................................. 113
Restraints on a Bend at 45º ........................................................... 115
Restraints on a Bend at 30º and 60º ............................................. 116
Vertical Dummy Leg on Bends ...................................................... 116
Vertical Leg Attachment Angle ...................................................... 120
Horizontal Dummy Leg on Bends .................................................. 120
Large Rotation Rods - Basic Model ............................................... 121
Large Rotation Rods - Chain Supports .......................................... 123
Bi-Linear Restraints ....................................................................... 124
Static Snubbers ............................................................................. 126
Plastic Hinges ................................................................................ 126
Sway Brace Assemblies ................................................................ 127
Anchors
Use the following guidelines when modeling anchors in CAESAR II:
The anchor default stiffness for translational and rotational degrees-of-freedom is defined in
the CAESAR II configuration file.
You can use connecting nodes with anchors to rigidly fix one point in the piping system to
any other point in the piping system.
The value that you define for the Stif property applies to all six anchor degrees-of-freedom.
Do not specify displacements at an anchor. If you know the displacements of a particular
point, specify them without any additional restraints or anchors.
Accurate definition of piping boundary conditions (restraints) is considered the single most
important part of system modeling. It requires experience with piping fabrication and
erection and with CAESAR II.
The example below shows a nozzle connection modeled as an anchor, along with the
corresponding rigid anchor input on the Restraints Auxiliary Data tab in the Classic Piping
Input dialog box.
Flexible Anchors
Use the following guidelines to model flexible anchors in CAESAR II:
Use six flexible restraints.
Refer to the following flexible nozzle examples to improve modeling methods for
intersections of this type.
For more information about defining restraints, see "Restraints" in the CAESAR II
User's Guide.
The CNode in the example below is 1005. CNode numbers must be unique.
Do not specify displacements for the nozzle node. Refer to the displacements at flexible
nozzles below.
CAESAR II automatically performs the following functions:
Calculates nozzle flexibilities for user-defined nozzle/vessel data.
Calculates and inserts restraints to simulate nozzle flexibilities.
Calculates flexibilities for the axial translations, circumferential, and longitudinal bending.
You must complete the error check process to view these calculated values.
CAESAR II uses the following criteria for its calculations:
Shear and torsional stiffnesses are assumed rigid.
Nozzle configurations outside of the WRC 297 curve limits are considered rigid. It is not
unusual for one stiffness value to be rigid because of curve limits and for the others to be
suitably flexible.
You can use Vessel Temperature and Material in the WRC 297 auxiliary data area to
optionally compute a reduced modulus of elasticity for the local stiffness calculations.
Nozzle Calculations
An example of the WRC 297 results found at the end of error checking is shown below.
Double-Acting Restraints
Double-acting restraints are those that act in both directions along the line of action. The most
commonly used restraints are double-acting.
A CNode is the connecting node. If you do not enter a value in the CNode box, the restrained
node is connected using the restraint stiffness to a rigid point in space. If you do enter a value
for CNode, the restrained node is connected using the restraint stiffness to the connecting node.
If you specify a gap, it is the amount of free movement along the positive or negative line of
action of the restraint before resistance to movement occurs. A gap is a length, so it is always
positive.
Translational Restraints
Restraint acts along both the positive and negative directions. Friction at double-acting restraints
acts orthogonally to the line of action of the restraint.
Rotational Restraints
The behavior of rotation restraints is similar to double-acting translational restraints. Friction is
not defined for rotational restraints.
Single-Directional Restraints
The following are some important facts pertaining to single-directional restraints:
The plus or minus sign (+/-) on the single-directional restraint gives the direction of free
movement. For example, a positive Y restraint (+Y) can move freely in the positive
Y-direction and is restrained against movement in the negative Y-direction.
Single-directional restraints can define restraint along positive, negative, or skewed axes.
Any number of single-directional restraints can act along the same line of action. If more
than one single-directional restraint acts along the same line of action, then there are usually
two in opposite directions and are used to model unequal leg gaps.
A CNode is the connecting node. If you do not define a value for CNode, then the
restrained node is connected using the restraint stiffness to a rigid point in space. If you
enter a value for CNode, then the restrained node is connected using the restraint stiffness
to the connecting node.
You can specify friction and gaps with single-directional restraints. The gap is in the
opposite direction of the free travel.
Guides
Use the following guidelines when modeling guides in CAESAR II:
Guides are double-acting restraints with or without a specified gap.
You can use connecting nodes (CNodes) with guides.
You can define guides using the global system coordinates or using the applicable options
in the restraints auxiliary data area.
The restraints auxiliary data area displays when you select Restraints on the
Classic Piping Input dialog box.
A guided pipe in the horizontal or skewed direction has a single restraint, acting in the horizontal
plane, orthogonal to the axis of the pipe.
A guided vertical pipe has X- and Z-direction supports.
CAESAR II computes direction cosines for guides. The software ignores user-defined guide
direction cosines.
Limit Stops
Use the following guidelines when working with limit stops in CAESAR II:
Limit stops are single- or double-acting restraints whose line of action is along the axis of the
pipe.
The plus or minus sign (+/-) on the single-directional restraint gives the direction of unlimited
free movement.
A limit stop and a single-directional restraint can have gaps. The gap is the distance of
permitted free movement along the restraining line of action.
A gap is a length and is always positive. The plus or minus sign (+/-) on the restraint
determines the orientation of the gap along the line of action. The gap direction is opposite
to the direction of free travel.
You can use connecting nodes (CNode) with any limit stop model.
A limit stop can be defined using the restraint type LIM.
Limit stops provide double- or single-acting support parallel to the pipe axis. Limit stops can
have gaps and friction. The positive line of action of the limit stop is defined by the From
and To node on the element.
CAESAR II computes direction cosines for orthogonal or skewed limit stops. The software
ignores user-defined limit stop direction cosines.
The stop at node 195 permits unlimited free movement in the negative
X-direction and 1.0 inches of free movement in the positive X-direction.
Windows
Use the following guidelines when modeling windows in CAESAR II.
Equal leg windows are modeled using two double-acting restraints with gaps orthogonal to
the pipe axis.
Unequal leg windows are modeled using four single-acting restraints with gaps orthogonal to
the pipe axis, as shown in the example below.
The gap is always positive. The plus or minus sign (+/-) on the restraint determines the
direction of movement before the gap closes. If there is no plus or minus sign (+/-) on the
restraint, then the restraint is double-acting, and the gap exists on both sides of the line of
action of the restraint. If there is a plus or minus sign (+/-) on the restraint, then the gap
exists on the restrained line of action of the restraint. For example, a positive Y (+Y) restraint
is restrained against movement in the negative Y-direction. Any gap associated with a
positive Y restraint is the free movement in the negative Y-direction before the restraint
begins acting.
In the example above, ignoring other loads that may be acting on the pipe, the
0.250-inch gap will be closed in the negative X-direction, and the pipe will have a displacement
of 0.50-inches in the positive X-direction.
Restraint Settlement
Use the following guidelines when modeling restraint settlement in CAESAR II:
Model restraint settlement using a single-directional restraint with predefined displacements.
The magnitude of the predefined displacement is the amount of anticipated settlement in the
negative Y-direction.
The operating load case is used to include the effect of settlement.
The settlement displacements are prescribed for the connecting node at the single
directional restraint. For more information, see Single-Directional Restraint with Predefined
Displacement (page 107).
Settlement is considered to be an EXP load with a half-cycle.
Restraint Settlement
Figure 11: Input Using Unit Direction Figure 12: Input Using Direction Cosines
Vectors
Figure 13: Input Using Perpendicular Figure 14: Input Using Guide Restraint Type
Vector
On Curvature Method
Easy input
Dummy leg acts at the proper place on the bend curvature
Dummy leg does not act along the centerline of the vertical run
In the example below, the rod pivots about the structural steel support. There is a very short
swing arm, so even a small amount of horizontal movement produces a relatively large swing.
The output report for this restraint shows X- and Y-direction loads.
Chain Supports
Bi-Linear Restraints
Bi-linear restraints are used most often to model soil support where some soil ultimate load
bearing capacity can be calculated. Bi-linear restraints are designated by typing a 2 immediately
after the direction in the restraint Type box.
Static Snubbers
Static snubbers are translational restraints designed to provide resistance to dynamic loads
such as seismic and wind. Snubbers are activated by checking the Snubbers Active? check
box for the appropriate load case (the one that contains the occasional load) on the Load Case
Options tab in the Load Case Editor. The figure below shows that snubbers will be active in
load case L2 to restrain the pipe against the uniform load.
Static snubbers, or static analysis snubbers, have SNB following the translational direction that
displays in the restraint Type box (located on the Classic Piping Input dialog box). After you
enter a snubber, Gap and Mu are no longer available.
Static snubbers can be directional. That is, they can be preceded by a plus (+) or minus (-) sign.
To model static snubbers, follow the steps below.
1. Run the operating case without defining a snubber.
2. Note the displacements, in all six degrees of freedom, at each snubber location.
3. In the Classic Piping Input dialog box, add each snubber with a distinct CNode.
4. Place the displacements from Step 1 on all snubber CNodes.
5. Modify the load cases by including D1 everywhere that T1 displays.
6. Activate snubbers in the Load Case Editor for all load cases containing occasional loads.
Plastic Hinges
The steps in setting up a plastic hinge are illustrated below. The leg from A to B is overheated,
causing bending of the B-D support leg. This example models the plastic deformation at
cross-section E-E. The plastic hinge is formed between nodes 10 and 15. The expansion joint is
used to provide translational and torsional rigidity at the plastic hinge junction. Two bi-linear
supports are used to model rigid resistance to bending until a breakaway force (yield force) is
exceeded, at which point bending is essentially free.
1The plastic hinge is modeled as a zero length expansion joint with rotational
bi-linear restraints.
A more specific sway brace selection is possible when the exact restraining force required to
control the piping vibration is known. The energy necessary to control the piping is proportional
to the mass, amplitude of movement, and the force causing the vibration. From this relation, the
exact restraining force required to control the piping vibration can be calculated and an
appropriate sway brace size selected.
After it is selected, the sway brace can be modeled in CAESAR II using a combination of a
bi-linear restraint and a translational restraint:
In the event that the sway brace is to be installed in the operating condition (or the neutral
position is to be adjusted in the operating position), the modeling in CAESAR II is a little more
complex. In this case, before modeling the sway brace, you must analyze the piping system
without the sway brace to obtain displacements from the cold to neutral operating position:
Run an analysis on the system without the sway brace to obtain the displacements from cold to
operating condition. In the example illustrated below, the assumed CAESAR II-calculated
displacement from cold to operating position is 0.5 inches
In the SUS case, the displacement D2 (vector 2) represents the pre-load in cold position. Under
shutdown conditions, the pipe returns to its cold position and the brace exerts a force as
previously described.
Sustained case restraint loads on sway brace = Pre-Load + Hot Deflection * Spring Rate
In OPE, the displacement allows thermal expansion, and the sway assumes neutral position
exerting zero or negligible load on the pipe.
Operating case restraint loads on sway brace =~ 0.0 (does not restrain thermal expansion)
Hangers
This section illustrates methods for incorporating spring hanger design into CAESAR II models.
For detailed information about using the software to define hangers, see Hangers in
the Boundary Conditions section of the CAESAR II User's Guide. For more information on how
CAESAR II selects hangers, see Hanger Sizing Algorithm in the Technical Discussions section
of the CAESAR II User's Guide.
In This Section
Simple Hanger Design ................................................................... 131
Single Can Design ......................................................................... 132
Constant Effort Support Design ..................................................... 133
Constant Effort Supports - No Design ........................................... 134
Existing Springs - No Design ......................................................... 135
Multiple Can Design ....................................................................... 136
Old Spring Redesign ...................................................................... 137
Cold Spring .................................................................................... 138
Pipe and Hanger Supported from Vessel ...................................... 139
Hanger Design with Support Thermal Movement.......................... 140
Hanger Between Two Pipes .......................................................... 141
Hanger Design with Anchors in the Vicinity ................................... 142
Hanger Design with User-Specified Operating Load ..................... 144
Simple Bottomed Out Spring ......................................................... 145
Lift Off Spring Can ......................................................................... 146
Modeling Spring Cans with Friction ............................................... 147
Cold Spring
See the "Technical Discussions" section of the CAESAR II User's Guide for a detailed
discussion of the method for analyzing cold springs.
Cut Short
You must first disable Connect Geometry Through CNodes in the Geometry
Directives category of Tools > Configure/Setup. For more information, see "Configuration and
Environment" in the CAESAR II User's Guide.
You must first disable the Connect Geometry Through CNodes configuration option
to avoid plot and geometry errors. For more information, see "Configuration and Environment" in
the CAESAR II User's Guide.
The anchor at 5 is freed in the Y-direction; the anchor at 105 is freed in all directions.
Simple bottomed-out spring restraints are used most often to conveniently enter predefined
springs into the piping system model. These spring restraints provide a bottoming out capability
that occurs when the spring has exceeded its maximum travel limit.
Always enter the stiffness Stif, the allowed travel "x", and the initial load on the spring F, to use
the bottomed out spring model. If the travel "x" is not entered, it defaults to zero. If the initial
load is not entered it also defaults to zero, and its sign is positive. No hanger should be entered
at the same position as a bottomed out spring.
Known information:
Theoretical Installed Load = 1023 lb.
Spring Rate = 260 lb./in.
K1 = Spring Rate
FY = 1023 pounds - 910 pounds = 113
pounds
Alternatively, element 15-20 can be omitted with the +Y restraint (with friction) placed directly on
node 15.
This modeling technique can also be used in situations where the shoe or trunnion
slides on top of a bolted spring can.
Expansion Joints
This section provides guidelines and recommended best practices for modeling expansion joints
in CAESAR II.
In This Section
Universal Expansion Joints - Simple Model .................................. 148
Tied Bellows Expansion Joint - Simple Model ............................... 152
Universal Joint with Lateral Controls Stops - Comprehensive Tie Rod
Model ............................................................................................. 155
Hinged Joint ................................................................................... 156
Slotted Hinge Joint - Simple Model ............................................... 157
Slotted Hinge Joint - Comprehensive Model ................................. 159
Tied Bellows - Simple vs. Complex Model .................................... 160
Slip Joint ........................................................................................ 161
Gimbal Joints ................................................................................. 163
Tied Bellows Expansion Joint - Complex Model............................ 164
Dual Gimbal ................................................................................... 165
Simple Bellows with Pressure Thrust ............................................ 167
Pressure-Balanced Tees and Elbows ........................................... 170
Universal Joint - Comprehensive Tie Rod ..................................... 171
Expansion Joint Rating analysis module works only on single bellows, which requires that you
first model and then check each bellows in the universal assembly.
Some manufacturers believe that friction at the tie bar ends, plus other effects, serve to limit the
overall lateral flexibility of this joint. A 10% increase in overall lateral stiffness is sometimes used
to compensate for these frictional effects.
The complex models are built by running pipe elements, whose diameters are equal to the
diameter of the tie bars and whose wall thicknesses are equal to half of the tie bar diameter,
between rigid elements that extend normal to the pipe axis and from the centerline and to their
intersection with the tie bar centerline.
The weights of the bellows and associated hardware are added to the flange weights on either
side of the bellows. This is particularly true if the expansion joint is between a hanger to be sized
and an anchor.
Field situations, such as loose nuts on tie bars, can be modeled using the complex expansion
joint model.
Descriptions of various universal models are shown below. Each model also includes example
inputs. Only use simple models when you know that both ends of the tie bars are fixed to the
flanges, that is, when there are nuts on both sides of the flange.
The top drawing shows nuts on only one side of the flange at the left end. Model this
configuration with a complex joint model unless you are certain that all tie bars will remain in
tension.
The top model is used when you are given global assembly data for the universal, such as the
assembly lateral stiffness. The second model is used when you are given angular spring rates
for each of the two bellows used in the model.
When provided equivalent single bellows lateral stiffness for the whole assembly:
Build the CAESAR II model of the flexible portion of the expansion joint. The rotational restraints
between nodes 29 and 30 keep the two flanges parallel, which assumes three or more tie rods.
In the field, the tie bars at four points around the expansion joint keep the flanges parallel.
The flanges and the tie bars form a parallelogram upon lateral deflection.
The following groups illustrate the method used to construct the universal joint with lateral stops
shown above. Only the right-side tie rod elements are shown below.
— Standard pipe elements —
34-36 / 36-38
— Rigid flange elements —
30-32 / 40-42
— Bellows elements —
32-34 / 38-40
— Rigid elements from the pipe to the tie bar centerline —
(Normal to the pipe axis)
30-1030 / 36-1036 / 42-1042
— Tie bar elements —
1003-1002 / 1002-1001
— Restraints with connecting nodes —
RESTR NODE=1001 CNODE = 1042 TYPE = +Y , X , Z
RESTR NODE=1002 CNODE = 1036 TYPE = Y w/gap=1.5 , X , Z
Hinged Joint
Hinged joints use a zero-length expansion joint with rigid axial, transverse, and torsional
stiffnesses. The bending stiffness equals the bending stiffness of the hinge.
You define the hinge directions using restraints and connecting nodes. The restraint line of
action is always normal to the hinge axis.
Manufacturers define hinged joints to take pressure thrust. Verify that the joint manufacturer is
aware of the design loads in the hinges.
Some expansion joint manufacturers believe that the hinge friction can provide considerable
additional resistance to bending. As the axial load that the hinge carries becomes large, the
hinge friction effect increases. You can make approximations to this increase in bending
stiffness by increasing the stiffness of the bellows proportionally to the axial load on the hinge.
The expansion joint manufacturer can help in determining this.
Typical geometries for hinged expansion joints are shown in the following figures:
In the next example, the hinged joint is zero length and is defined between nodes 45 and 46. X
is the hinge axis, meaning that all relative rotations are permitted between nodes 45 and 46
about the X-axis. Nodes 45 and 46 are fixed rotationally relative to each other in the Y-axis.
The table below shows the input data used for the hinged joint as shown above.
In the example model shown above, the software presumes the relative rotation at the
hinge about the Y-axis to be zero. The slots on either side provide some limit to this Y rotation.
In most applications of this type, the relative Y rotation is zero because the problem is kept
planar using guides. A good first pass can be made using the model shown. If the analysis
shows that the RY restraint between nodes 15 and 16 is supporting load, a further refinement to
the model can be made.
Zero weight rigid elements that define the hinge assembly are listed below:
10 - 15 Normal to pipe axis to centerline of hinge assy.
10 - 35 "
55 - 30 "
55 - 50 "
15 - 20 Parallel to pipe axis to centerline of hinge axis.
35 - 40 "
50 - 45 "
30 - 25 "
The finite length bellows must be defined accurately between nodes 10 and 55. Typically, this
means entering the correct flexible length and using the manufacturer’s axial and lateral spring
rates.
The manufacturer’s published angular spring rates may not be appropriate for use in
finite length expansion joint models.
Use a complex model when any the following Use a simple model when any of the following
conditions exist: conditions exist:
You are investigating a failure. The tie bars are either guaranteed to be
carrying tension or have nuts on either
The pipe diameter and number of
side of the flange and can carry
convolutions become large.
compression, if needed.
The nuts are only on the outside of the
There is no relative rotation of the ends.
flange, allowing the tie bars to only carry
tension.
You have good values for the load
distribution in the tie bars. Simple models
give no indication of the load distribution. In
cases where the tie bars combine to resist
relative bending of the joint ends, one pair
of tie bars can be in compression while the
other pair is in tension. This effective
redistribution of load in the tie bars is never
observed in a simple model. When this
does occur, and if the tie bars are very
long, buckling of the rods in the complex
model should be investigated (evaluate
whether the rods can withstand the
compressive forces reported in the output
report).
Because of the uncertainty of the application, enter the lateral instead of the bending spring rate
from the manufacturer’s catalog.
Add the weights of the bellow and associated hardware to the flange weights on either side of
the bellow. This is particularly true if the expansion joint is between a hanger to be sized and an
anchor.
When using expansion joints, verify that the displacement limits for the expansion joint after the
protected equipment loads are within the allowables. In CAESAR II, you can use the Analysis >
Expansion Joint Rating command to help compute relative bellow movements for evaluating
the bellow distortion.
You can build simple models of single tied bellows by entering a large axial stiffness. This axial
stiffness simulates the tie bars, preventing relative axial movement of the bellows. You can
model tie rods with a single rigid element along the centerline of the bellow. With zero weight
and rotational restraints, this prevents the ends of the joint from rotating relative to one another.
In reality, the tie bars being offset from the centerline prevent this rotation.
You can build complex models of tied bellows by running pipe elements whose diameters are
equal to the diameter of the tie bars, and whose wall thicknesses are equal to half of the tie bar
diameter, between rigid elements that extend normal to the pipe axis and from the centerline
and to their intersection with the tie bar centerline. For more information on building complex
models, see the Tied Bellows Expansion Joint - Complex Model (page 164).
Some manufacturers believe that friction at the tie bar ends, plus other effects, serve to limit the
overall lateral flexibility of this joint. A 30% increase in lateral stiffness is sometimes used to
compensate for these frictional effects. Field situations, such as loose nuts on tie bars, can be
modeled using the complex expansion joint model.
Slip Joint
Large slip joints are usually difficult to install and difficult to accurately model.
Smaller diameter slip joints are telescoping, axial displacement devices that permit considerable
axial displacement of the slip joint ends and moderately rigid resistance to pipe bending. They
are usually categorized as having two annular packing glands that are separated axially along
the joint by a dead air space or by a small bellows sleeve.
The following figure shows the cross-section of a typical large slip joint. The stiffnesses between
nodes 15 and 25 are a function of the packing stiffness for transverse and rotational relative
deformation and of packing stiffness and tightening for axial relative deformation.
Slip Joint
Where (N) is the nominal pipe diameter in inches, and (a) is the thermal expansion at
the operating temperature in inches per 100feet.
FY is the joint friction thrust from the vendor catalog. Typical values are given as 400
pounds multiplied by the nominal pipe size.
Gimbal Joints
Gimbaled joints are designed to resist pressure thrust. CAESAR II recommends that you verify
that the joint manufacturer is aware of the design loads on the gimbals. External loads are not
always given. If axial loads are given, the bellows designer must know whether it includes or
excludes pressure thrust.
You can model the angular-only gimbal as a zero length expansion joint with rigid axial,
transverse, and torsional stiffnesses. The bending stiffness is set equal to the rotational stiffness
specified in the manufacturer's catalog.
CAESAR II recommends that you thoroughly model angular and offset gimbals, as shown in the
following figures. Angular and offset gimbaled joints are usually installed in large diameter lines
where lumped-property assumptions for the bellows may not be within reasonable engineering
accuracy.
Rigid elements between nodes 105 and 110 and nodes 111 and 115 each contain
half the weight of the hinge mechanism.
Dual Gimbal
Dual gimbal joints are two, usually angular-only, gimbaled joints in series in the pipeline. Putting
two (or three) angular-only gimbaled joints together provides the ability to absorb lateral and
possibly axial deformation.
Pipe flexibility software is unable to model the axial-only component of the possible
deformation because it requires large rotation of the expansion joint components.
Use the single angular deformation only gimbals in series with at least one other gimbaled joint.
It is only in series that the angular deformation only gimbal provides for any lateral movement.
Gimbaled joints are designed to take pressure thrust. Verify that the joint manufacturer is aware
of the design loads on the gimbal. Model each individual angular-only gimbal joint as a zero
length expansion joint with rigid axial, transverse, and torsional stiffnesses. Ensure that the
bending stiffness is equal to the manufacturer's published rotational stiffness term.
The minimum required distance, or L, between adjacent single gimbaled joints (shown as 8-7 in
the following example) is principally a function of the angular and rotational deformation to be
absorbed, the diameter, and the number of convolutions per joint. The following figure shows a
dual gimbal comprised of two angular-only gimbals. The bending stiffness for each gimbaled
joint is 490.0-inches lb./deg.
Most expansion joint manufacturer's catalog values for bending stiffness are still based on
zero-length bellows, while the transverse stiffness is normally based on the finite-length of
bellows. For more information refer to equations (1) and (2) above. For this reason, enter the
transverse stiffness and leave the Bending Stif box blank. CAESAR II then calculates the
proper bending stiffness according to equation (3) and uses this value for the flexibility analysis.
If you enter a value for KTR that does not conform to equation (1), equation (3) uses the entered
value to calculate Kb.
If a catalog value of Kb is used and that value is based on zero-length values,
CAESAR II uses equation (4), which results in one-quarter of the value of KTR.
For a zero length expansion joint, CAESAR II uses either the preceding or the following
element to determine the axial direction of the bellows stiffnesses. The preceding element is
checked first.
Bellows are very fragile under torsional loading. Accurate torsional stiffnesses and allowable
torsional rotations should be obtained from the vendor.
Systems using untied bellows should either be of very low pressure or adequately anchored
and guided to withstand the possibly large thrust loads developed due to the unrestrained
bellows.
Bellows and any other miscellaneous weights should be added to flanges on either side of
the bellows, or can be added as concentrated forces. This is particularly true when the
bellow is part of a hanger sizing weight calculation.
A zero or blank Effective ID results in a zero pressure thrust. The Effective ID is the mean
diameter of the bellows and is used to find the area for pressure thrust calculations. The total
thrust load is applied at the From and To ends of the bellows and is used to open the bellows if
the pressure is positive. The magnitude of the thrust load is P × Aeff, where P is the pressure in
the pipe above atmospheric, and Aeff is the area, found from
Aeff = π/4 × (DEff)2
Many manufacturers specify the effective area of the bellows. The Effective ID for CAESAR II
input can be calculated using the following equation:
Deff = [4Aeff /π]½
In the example below, the untied bellows runs between nodes 8 and 9. The elbow at node 11 is
anchored to take the thrust load developed in the bellows. The manufacturer's specification for
the axial stiffness of the joint is 5131 lbs/in. with a transverse stiffness of 27058 lbs/in. The
bending stiffness is left blank and is calculated by CAESAR II because the bellows has a finite
length. The pump and the baseplate at node 5 must be able to withstand the large axial force
that develops due to pressure thrust in the bellows.
Aeff = 69 in2
P = 175 psi
Thrust = 69(175)=12075 lbs.
(automatically applied by
CAESAR II)
The example below shows the coding of a pressure-balanced tee in a turbine exhaust line. The
bottom side of the tee is blanked off. The tee is a standard, unreinforced fabricated tee. The tie
bars only act in tension.
The following groups illustrate the method used to construct the universal expansion joint model
shown above.
—Rigid Elements (Flanges) —
15-17 / 31-33
—Rigid Elements normal to the pipe axis and between the pipe and tie bar
centerlines.
Used at the end where there are nuts on either side of the flange, fixing the tie bar to the flange:
33-1033 / 33-2033 / 33-3033
—Rigid Elements normal to the pipe axis, and between the pipe and tie bar
centerlines.
Used at the end where there are nuts only on the backside of the flange:
15-1015 / 15-2015 / 15-3015
——Intermediate lateral tee supports (Rigid) —
23-1023 / 23-2023 / 23-3023
25-1025 / 25-2025 / 25-3025
——Tie bars —
1033-1034-1035-1036
2033-2034-2035-2036
3033-3034-3035-3036
— Restraints with connecting nodes at the tension-only flange end.——
RESTR NODE = 1036 CNODE = 1015 TYPE = -X , Y , Z
RESTR NODE = 2036 CNODE = 2015 TYPE = -X , Y , Z
RESTR NODE = 3036 CNODE = 3015 TYPE = -X , Y , Z
— Restraints with connecting nodes at the intermediate support points.
RESTR NODE = 1035 CNODE = 1023 TYPE = Y , Z
RESTR NODE = 2035 CNODE = 2023 TYPE = Y , Z
RESTR NODE = 3035 CNODE = 3023 TYPE = Y , Z
Examples
This section provides examples for a variety of design challenges faced by piping engineers.
In This Section
Reducers........................................................................................ 173
Ball Joints....................................................................................... 174
Jacketed Pipe ................................................................................ 176
Vertical Vessels ............................................................................. 178
Horizontal Vessels ......................................................................... 183
Harmonic Analysis (TABLE) .......................................................... 187
Relief Valve Loads (RELIEF) ......................................................... 191
Dynamic Analysis of Water Hammer Loads (HAMMER) .............. 200
Dynamic Analysis of Independent Support Earthquake Excitation
(CRYNOS) ..................................................................................... 214
Structural Analysis (FRAME) ......................................................... 226
Dynamic Analysis (NUREG9) ........................................................ 233
Omega Loop Modelling (OMEGA) ................................................. 241
Jacketed Piping (JACKET) ............................................................ 246
WRC 107 ....................................................................................... 256
Reducers
1. Define the reducer length as you would any pipe element.
For eccentric reducers, skew the element so that the To node matches the
centerline of the following pipe elements.
2. Double-click the Reducer check box on the Classic Piping Input dialog box.
If the elements preceding and following the reducer are already defined (such as if
you are inserting this element) then CAESAR II automatically calculates all of the reducer
input data. In that case, leave the Reducer Auxiliary Data tab fields blank.
3. Type the diameter and wall thickness of the pipe that follows the reducer.
You can type nominal diameter and wall thickness and CAESAR II will convert these to
actual diameter and wall thickness if this option is activated in the units file. (If the
Diameter and Wt/Sch boxes on the Classic Piping Input dialog box convert nominal to
actual, then the Reducer Auxiliary Data tab boxes will also make this conversion.)
Alpha is the slope of the (concentric) reducer transition in degrees. If unspecified,
CAESAR II calculates alpha using 60 percent of the entered reducer length.
Alpha = atan[ (D1-D2) / (2*length of the sloped portion of the reducer*0.6) ]
IGE /TD -12 requires entry of the reducer Alpha as well as R1 and R2 (the reducer
transition radii of the large and small ends).
Reducer Example
Ball Joints
Ball joints can be modeled with zero-length expansion joints, or with restraints and connecting
nodes. When using expansion joints, each ball and socket is defined with one zero-length
expansion joint having rigid axial and transverse stiffnesses and zero bending and torsional
stiffnesses.
If torsional stiffness is small, use a value of 1.0.
Results are invalid for large rotations.
Method 1
Modeling a ball joint between nodes 20 and 21
using a zero-length expansion joint. Input Specifics
Node-CNode Model
Method 2
Modeling a ball joint between nodes 20 and 21
using axial, translational restraints with CNodes. Input Specifics
The next element starts at node 21 (the From
node).
Node-CNode Model
Jacketed Pipe
Jacketed piping systems are modeled by running the jacket elements directly on top of the core
elements so that the two are concentric.
You can generate a jacketed pipe model by modeling the entire core and then duplicating the
core piping using an appropriate node increment (such as 1000). This produces a second run of
pipe which is modified to build the jacket model. For the jacket, change the pipe size,
temperature, bend radii, and so on, to finish the model. Then, attach the jacket and core by
changing the node numbers and adding restraints.
Typically, the end caps connecting the core to the jacket pipe are much stiffer than either the
core or the jacket. For this reason, node pairs like (10 and 1010), (25 and 1025), (35 and 1035),
and (40 and 1040) are often joined by using the same node for each. For example, the
displacements and rotations at the end of the core pipe are assumed to be the same as the
displacements and rotations at the end of the jacket pipe.
Internal spiders offer negligible resistance to bending and axial relative deformation. Node 15
might be connected to node 1015 by a restraint with a connecting node. For an X-run of pipe,
rigid restraints would exist between the two nodes for the Y- and Z-degrees of freedom.
The +Y support acting on the jacket at node 1020 does not cause any stiffnesses to be inserted
between 20 and 1020. Node 20 is included in the model so that the outside diameter
interference can be checked at the 20-1020 cross sections. If there is any concern about
interference or interference-related stresses at the 20-1020 nodes, then you can use restraints
with connecting nodes and gaps to approximate the pipe-inside-a-pipe with clearance geometry.
Because CAESAR II constructs the jacketed piping model by associating nodal degrees of
freedom, the software does not know one pipe is inside of another. Therefore, consider the
following items:
If both the jacket and the core are fluid-filled, the fluid density of the jacket must be reduced
to avoid excess (incorrect) weight.
If wind or wave loads are specified, the wind or wave loading must be deactivated for the
core so that the core does not pick up the load.
The core pipe should probably have its insulation thickness set to zero.
Vertical Vessels
Average diameter of the skirt = 102 + 78/ 2 = 90 inches.
Average temperature of the skirt = 87º F.
Temperature of the vessel = 325º F.
Nozzle N1:
OD = 10.750.
Wall = 0.5.
Length of Flange = 4.0 inches.
Weight of single flange = 112.
Element 20 to 125 is rigid. The associated diameter and wall thickness are that of the
vessel. The element from 20 to 125 is stiff relative to the vessel. The element from 15 to 215
is stiff relative to the vessel.
The rigid element from 135 to 140 models the flange at the end of the nozzle and is rigid
relative to the nozzle diameter.
The rigid element 225 to 230 models the flange at the end of the nozzle and is rigid relative
to the nozzle diameter.
Local shell flexibilities are defined between 130 and 135 and 220 and 215.
The example considers the cantilever bending, the shear in the vessel from the skirt, and
the local flexibility of the vessel shell in the vicinity of the nozzle.
Vessel Skirt
The following partial dialog boxes illustrate the modeling techniques used to define the vertical
vessel.
Vessel
Rigid Elements
These rigid elements are weightless, but they do undergo thermal expansion.
N1 Nozzle
Flange
N2 Nozzle
Horizontal Vessels
Horizontal vessel models are built using combinations of straight pipe and nozzle flexibility
simulations (WRC 297). The following example illustrates the most accurate way to define
horizontal vessel flexibility.
NOZZLE N3:
OD = 12.750.
Wall= 0.687.
Flange length = 5.0 inches.
Flange weight = 250 lb.
Elements 5 to 6, 6 to 10, 15 to 16, 16 to 20, and 20 to 22 are rigid and the associated
diameter and wall thickness is that of the vessel. These rigid elements are stiff relative to the
vessel.
The rigid element from 26 to 30 models the flange at the end of the nozzle and are rigid
relative to the nozzle diameter.
Local shell flexibilities are defined between the nodes 22 and 24.
The above model considers the flexibility of the horizontal vessel section, the free translation
horizontal restraint at 15, and the local flexibility of the vessel shell in the vicinity of the
nozzle.
The following partial dialog boxes illustrate the modeling techniques used to define the
horizontal vessel.
Vessel Legs - portion not in contact with vessel T=100Fº, P=0.0psi
DY = Vessel Radius
The vessel flexibilities are calculated and reported during error checking. These values are used
automatically in the analysis. This WRC297 data is available to output in the Miscellaneous
Data report.
Enter the model as shown and set the material density on the pipe spreadsheet to be zero.
Enter all weights as concentrated masses. Do not enter bends; enter only straight elements.
Member Properties
Run the static case, and then click Dynamic Analysis on the CAESAR II toolbar. The
software opens the Dynamic Analysis dialog box.
On the Lumped Masses tab, you can add additional masses or delete degrees-of-freedom. In
the Eigensolution of larger systems, the deletion of un-needed degrees-of-freedom can be a
very important factor in keeping run times reasonable. Usually, masses must neither be added
nor deleted. The mass of the piping, fluid, and insulation is automatically calculated and included
by CAESAR II. In the current example, the weight of the pipe is zero, and all masses are
concentrated and predefined as lumped masses.
Next, use the Control Parameters tab to modify the control parameters as shown below:
Setting Frequency Cutoff (Hz) to zero turns it off, and setting Max. No. Eigenvalues
Calculated (0 - Not Used) to 5 guarantees that the first five natural frequencies are included in
the results.
Click Run the Analysis . When the Eigensolution is completed, the calculated natural
frequencies are printed as shown in the figure below.
You enter harmonic loads next. The software prompts you for harmonic forces first and then
prompts you for direction. In the example piping system, harmonic forces act at nodes 8 and 13.
The forces act in the X-direction with an opposite sign and with a magnitude of 95 pounds. The
force acting at node 8 can be plotted as a function of time as shown in the figure below.
The same force effect can be achieved by entering +95.0 pounds at each node and
entering a phase angle of 180.0 degrees at node 13.
Calculations for the example problem take less than 30 seconds to complete. You can view the
structure in animated motion or view standard displaced shape plots in the DynPlot window
using the Display Graphical Results option (as shown below). Additionally, harmonic results,
restraint loads, forces, and stresses can be calculated for the maximum displacements due to
the harmonic loads.
The spectrum table name is arbitrarily selected as Relief and is defined as having a Frequency
range and a Force-Multiplier ordinate. A # sign precedes the name in the spectrum definition
because the shock table is to be read from an ASCII file. The spectrum definition is shown as it
appears in the Dynamic Analysis dialog box is shown below:
The DLF Spectrum Generator builds the ASCII file, Relief, which contains the relief valve
spectrum table. You must define the filename, maximum table frequency, number of points, and
the time-history waveform. In the example shown below, a maximum frequency of 33 Hz and 20
data points are used to generate the table.
The points in the time history waveform are entered as shown below. These points represent the
opening of the valve, its one-second vent time, and its closing.
The Frequency versus Dynamic Load Factors is written to the file Relief. Click Save to File, and
then click OK to close the Spectrum Table Values dialog box.
The thrust loads act at points 65 and 100. These loads are defined on the Force Sets tab and
are entered as shown below.
There is only a single load case defined on the Spectrum Load Cases tab as follows:
Only one static/dynamic combination case is defined. It is the combination of the sustained static
load case with the dynamic load case. This is defined on the Static/Dynamic Combinations
tab as follows:
Only one item needs to be set on the Control Parameters tab. It defines the static load case for
setting the nonlinear restraints. In the following example, the setting is 3 (line 1). Alternatively,
you can set the modal combination method (line 11) to ABS instead of SRSS to produce
conservative results.
Mass Participation Report - Shows how sensitive each of the piping system’s modes is to
the relief valve firing. High modal participation factors indicate that the mode is easily excited
by the applied dynamic forces. If subsequent displacement, restraint, or stress reports
indicate excessive dynamic responses, then the modes having high participation must be
dampened or eliminated. After a particular mode is targeted as being a problem, it can be
viewed in tabular form using the mode shape report or graphically using the animated mode
shape plots.
Restraint Report - Shows the maximum dynamic load for which the support should be
designed. The top value is the maximum support reaction. The second value is the largest
support reaction due to any one mode. The last number on the left indicates which mode.
Stress Report - Shows the maximum dynamic stress due to the relief valve firing. Stresses
from a dynamic shock load case should be combined with the sustained stresses from a
static analysis and the result compared with the code defined occasional stress for the
material.
Participation Factor Report - Shows which modes tend to be excited by the applied
dynamic load.
The following Stress report shows element stresses due to the dynamic relief loads. The top
value is the maximum stress due to the interaction of all the system modes. The second value is
the largest stress due to any one mode. The bottom number on the left indicates which mode.
In the following examples, the maximum stress at node 5 is 1481 psi. The stress at node 5 due
only to mode #1 is 1280 psi.
The maximum stress at node 40 on elements 40-50 is 6430 psi. The stress at node 40 due to
mode #4 is 3982 psi. Mode #4 is the largest contributor to the stress at node 40.
Support reactions due to the combination of the static sustained and the dynamic solutions are
shown in the following two report samples:
This stress combination can be compared to the B31 code allowables for occasional stresses.
SOLUTION
The magnitude of the pump supply side pressure wave, which emanates from the pump
discharge at node 5, can be estimated from
dp = ρ c dv
Where:
dp = the pressure rise due to the pump’s instantaneous stopping
ρ = the fluid density
c = the speed of sound in the fluid
dv = the change in velocity of the fluid
The speed of sound in the fluid can be estimated from:
c = [Ef/(ρ+ ρ(Ef/E)(d/t))]0.5
Where:
Ef = the bulk modulus of the fluid (313000 psi)
E = the modulus of elasticity of the pipe (30E6 psi)
d = the pipe mean diameter
t = the pipe wall thickness
ρ = the fluid density (62.4 lbm/ft3)
For a more detailed discussion and evaluation of the speed of sound, see Piping
Handbook, Crocker & King, Fifth Edition, McGraw-Hill pages 3-189 through 3-191
Apply the previously mentioned equation for the magnitude of the water hammer pressure wave.
dp = ρ c dv = (62.4 lbm/ft3)(4281 ft/sec)(6.0 ft/sec)
= (62.4 lbm/ft3)(4281 ft/sec)(6.0 ft/sec)(lbf sec2/32.2 lbm ft)(ft2/144 in2)
= 345.6 psi
There are two distinct pressure pulses generated when a flowing fluid is brought to a stop. One
pulse originates at the supply side of the pump, and the other pulse originates at the discharge
side of the pump. This example only deals with the supply side water hammer effect, but the
magnitude and impact of the discharge side water hammer load should likewise be investigated
when in a design mode.
The time history waveform for both types of water hammer pulses is shown as follows:
CALCULATIONS
L 45-75 = 7 + 4(20) + 4 = 90 ft.
L 90-110 = 3(20) + 15 = 75 ft.
Area = Π/4di2; di = 8.625-(2)(0.322) = 7.981 in.
Three spectrum load cases are of interest in this example: each spectrum separately and
the two of them in combination.
The sustained static load case is now combined with each dynamic load case for code
stress checks. For operating restraint loads, the static operating case is combined with each
dynamic load case, if necessary.
If the pump or valve stops in a time shorter than T, then the water hammer should be analyzed
as shown in this example for instantaneous closure. Calculations for this problem are given
below.
Of primary interest is the largest time segment that must be used to close a valve or bring a
pump flowrate to a halt such that water hammer type pressure pulses are not generated.
Calculations using the lengths of several reflecting systems are made to determine the variation
of the computed Ts. The longest time is for the wave to leave the supply side at node 5 and
move to the tank connection at node 125. This represents a total L of about 270-feet.
T = (2) (270) ft./(4281)ft/sec = 126 milliseconds
The length through which the wave passes that causes the most trouble is the length between
nodes 45 and 75:
T = (2) (90)/(4281) = 42 milliseconds
If the pump or valve can slow down in greater than 126 milliseconds, the tendency for water
hammer in the piping system is usually abated. If the pump or valve can slow down in greater
than 42 milliseconds then the tendency for water hammer in the 45-75 length is abated.
Water hammer excitation initially produces axial acoustic waves in the steel pipe wall that can
induce locally very high, very short duration forces and stresses. These short duration loads are
usually not a design problem in ductile steel piping systems. Where crack propagation in welds
and material due to water hammer loads is a concern, use the following rules:
A very high number of natural frequencies must usually be included in the analysis. Cutoff
frequencies of 300 Hz are not unusual. These are the axial natural modes of the pipe
between the excited elbow-elbow pairs. Higher modes must be computed until the inclusion
of extra modes does not produce an appreciable change in the force/stress response. The
maximum frequency cutoff can be estimated using
SQRT (E/ρ)/L
Where:
E = Pipe material modulus of elasticity
p = Pipe material density
L = Length of a single pipe element in the primary run that is to have accurate stresses
computed due to the passing of the water hammer originated acoustic stress wave.
Calculation of the maximum cutoff frequency for the 45-75 elbow-elbow pair for the 20-foot
pipe lengths is given as follows:
fcutoff = SQRT (E/ρ)/L
= SQRT ((30E6)(32.2)(12)/(0.283))/20
= (202388 in./sec) / (20 ft. 12 in/ft)
= (843.3 rad./sec) / (2 p rad./cycles)
= 134.2 Hz
Alternatively, including the Missing Mass Correction approximates the contribution from the
omitted modes.
The length of any element in the primary axial runs should not be greater than about ct/4,
where c equals the speed of sound in the pipe and t equals the duration of the water
hammer load. Calculation of the greatest element length for the 45-75 elbow-elbow pair is
given as follows:
Lmax= ct/4
= (4281) ft/sec (0.021) sec/(4)
= 22.5 ft
To get an accurate estimate of the stresses due to the passing of the stress wave in the
pipe, individual element lengths should be smaller than about 20 feet. Shorter duration loads
require shorter elements to monitor the passing of the stress wave.
The inclusion of the response due to the higher modes does not affect the displacement
results (only the force and stress results). Displacement results, such as the 6- to 8-inches
in this example, can usually be computed accurately after the inclusion of the low frequency
modes with participation factors greater than about 0.01.
Restraint/Force/Stress Reports
If high modes are included, as discussed in Notes for Analyzing Water Hammer Loads (page
208), then these reports give the maximum values of the forces and stresses in the system due
to gross deformation and the propagation of an acoustic stress wave in the pipe. If the high
modes are not included, then these reports give the maximum values of forces and stresses in
the system due to gross deformation alone.
Displacement Report
This report gives the maximum possible positive or negative displacement that can occur at
some time during the event. Values in this report are always positive.
Combination Cases
The force spectrum approach to the water hammer problem does not include consideration of
the time relationship between modal or directional maximums. Conservative results can be
guaranteed by taking the absolute summation of both the modal and directional response
properties. Running one load case for each main piping run and a final load case, including all of
the individual load cases, can typically provide a good indication for where problems exist.
In this example, the main piping run between nodes 45 and 75 added the major contribution to
the system dynamic responses. The combination load case, which included the 45-75 and
90-110 contributions together, yielded little extra information.
Solution Summary
A guide and axial limit stop at nodes 45 and 105 produces little increase in thermal stresses,
which were low to begin with, and serves to attenuate the large axial displacements in the line
due to the water hammer load. Loads on this support due to the low mode displacements are
seen to be small. Local, very short duration loads may not be so small. The restraint should be
designed with this in mind.
A few simple design rules are usually sufficient:
Flexible is optimal. The restraint should only be stiff enough to sufficiently attenuate the low
frequency gross deformation.
Areas of local discontinuities, such as the weld of the support to the pipe, should have extra
weld or support plate area. Discontinuities at other restraints in a problem area should also
be reinforced to withstand the local passing of the impact stress wave.
.
The following table lists the excitation spectra to be applied to this model:
The necessity for the various spectra can be best understood by investigating the difference
between independent support excitation and uniform support excitation. These excitation
methods are shown in the following figures.
For the analysis with steel supports, the structural steel must be included as part of the piping
model. Click Environment > Include Structural Input Files. The structural data input is shown
below:
SECID=1, W14 X 82; COLUMN CROSS SECTION
SECID=2, W10 X 12; BEAM CROSS SECTION
MATID=1, YM=29E6 POIS=0.3 G=11E6 DENS=0.283
DEFAULT SECID=1
ANGLE=90
EDIM 1038 1039 DY=15-0; DEFINE ALL COLUMNS
EDIM 1043 1044 DY=15-0
EDIM 1048 1049 DY=15-0
EDIM 1053 1054 DY=15-0
DEFAULT SECID=2
ANGLE=0
EDIM 1039 1040 DZ=-2-0;DEFINE ALL BEAMS
EDIM 1044 1045 DZ=-2-0
EDIM 1054 1055 DZ=-2-0
FIX 1038 ALL
FIX 1043 ALL
FIX 1048 ALL
FIX 1053 ALL_
The dynamics input for this example is summarized in the following figure:
Details of the dynamics input are shown in the next four figures.
Only the results for the uniform support excitation case are shown. Using this load case, the
model with and without structural steel supports is compared. The results from these two models
are shown in the following tables.
With Structure
Without Structure
With Structure
Without Structure
With Structure
Without Structure
Results
These comparison tables illustrate the differences that can exist when the structural steel
models are not included in the analysis. In some cases, the results with the structural steel
included are many times higher than the results computed without the structural steel. The steel
models add flexibility to the piping system. More flexibility means lower natural frequencies and
more modes to be excited by the shock. A comparison of the natural frequencies of the two
models is given as follows:
With Structure
Without Structure
In the previous table, there are only five extra mode shapes for the system.
The restraint moment at node 55 in the Z-direction is much larger without the steel model than it
is with the steel model. Even though the piping is tied to the steel, the steel frame does not
support much moment in the Z-direction. The steel frame bends slightly about the Z-axis, and
the moment is carried through from the pipe. In the piping only model, the rigid anchor at node
55 does not rotate about the Z-axis (or any other axis), and ends up carrying the entire moment
load.
This example illustrates how to use most of the keyword directives in the structural
preprocessor. A standard finite element modeling approach is followed, where the system nodes
are defined first, followed by materials and section properties, elements, and finally the loading.
3. Click Save on the Structural Modeler toolbar to error check and save the model.
4. Click Yes in the Save changes to FRAME? message box.
5. Click OK in the Model Generation Status message box.
6. Click File > Exit to exit the structural steel input processor.
CAESAR II reads the binary files created by the structural preprocessor and displays
recommended load cases in the Static Analysis dialog box.
CAESAR II recommends load cases to satisfy piping code compliance and not
necessarily loads that you would want to use for structural analysis.
8. Edit the load cases as shown in the example below.
Load case 2 (L2) consists only of U1, which is designated as an operating case
(OPE). This is a construction case and is segregated here because it may be interesting to
see the loads produced by the Uniform Load.
1 9.360 9.362
2 12.71 12.708
3 15.38 15.379
4 17.80 17.800
5 21.60 21.606
6 25.10 25.102
7 32.03 32.039
8 38.07 38.075
9 40.29 40.299
10 48.90 48.905
11 57.51 57.524
12 61.50 61.510
13 62.54 62.550
14 69.35 69.359
15 77.44 77.456
16 78.88 78.893
17 101.7 101.731
18 103.6 103.598
19 108.0 107.983
20 115.1 115.116
21 135.2 135.265
22 155.2 155.244
23 160.6 160.626
24 203.8 203.820
25 209.9 209.957
TRANSLATIONS (in)
DX DY DZ
ROTATIONS (deg)
RX RY RZ
1 90 90 65 64 177 177
7 0 0 0 0 708 707
9 446 445 0 0 0 0
11 0 0 206 206 0 0
13 0 0 164 164 0 0
DX DY DZ
ROTATIONS (deg)
RX RY RZ
1 53 53 46 46 113 112
7 0 0 0 0 441 440
9 257 256 0 0 0 0
11 0 0 123 123 0 0
13 0 0 98 98 0 0
17 32 32 124 123 66 66
TRANSLATIONS (in)
DX DY DZ
DX DY DZ
ROTATIONS (deg)
RX RY RZ
1 76 76 70 69 156 155
FX FY FZ
7 0 0 0 0 607 607
9 350 350 0 0 0 0
11 0 0 184 184 0 0
13 0 0 146 146 0 0
17 45 45 169 168 91 90
The example uses an Omega loop as shown below. The given dimensions are the 6-ft 10-in.
height, the 2-ft bend radius, and the bend angles of 135° and 270°. Using this information, you
can derive the other dimensions shown in the following figure.
Equation 1: Figure 1
Equation 1: Figure 1
When coding a series of back-to-back bends, it is important to remember that the delta
dimensions should be measured from the tangent intersection point (TIP) to the tangent
intersection point.
For more information about the proper coding of bends, see Bends (page 78).
Figure 2 shows the node points, which are coded on the Classic Piping Input dialog box to
model the Omega loop. The model is anchored at nodes 1 and 35. The first bend (lower left
bend) spans between nodes 5 and 10. The TIP 10 is to the far right of the bend. For analysis
and output, the actual location of node 10 is at the far weld line, as shown in Figure 3.
Equation 2: Figure 2
Equation 2: Figure 2
The second bend (upper left bend) spans between nodes 10 and 15. Because you can code TIP
to TIP, the delta coordinates entered in the Classic Piping Input dialog box are the X and Y
distances between nodes 10 and 15 (Figure 2). The actual location of node 15 is at the far weld
line, shown on Figure 3. Node 15 is the TIP for this bend and lies to the left of the pipe.
The third bend (upper right bend) spans between nodes 15 and 20, where node 20 is the TIP. In
coding from TIP to TIP, only a delta x is required. Figure 3 shows the actual location of node 20
on the pipe.
The fourth and final bend (lower right bend) spans between nodes 20 and 25. In this case, a
delta X and a delta Y are required. The actual location of node 25 is shown on Figure 3. The
element from 25 to 30 is a straight element necessary to finish off the bend.
A bend in CAESAR II requires an element beyond the far weld line to determine its
orientation.
Equation 3: Figure 3
Equation 3: Figure 3
Below is an input listing for the model. The delta dimensions shown were obtained from Figure
1. Three additional, equally-spaced points are located on each bend.
This example requires a change in the CAESAR II Configuration Editor to allow the
error checker to accept large angle (> 95°) bends. \
Click Tools > Configure / Setup to open the CAESAR II Configuration Editor. In the
Categories pane, click Geometry Directives and set Maximum Allowable Bend Angle to
135.
In some systems, the jacket and the core consist of different materials. This condition
must be modeled very carefully because the thermal growth in the core is different from the
thermal growth of the jacket. Improper axial restraints in such a system can cause extremely
large loads in the pipe.
Modeling Plan
The first step in modeling any system is to consider the most efficient way to create the input
and, more importantly, how to best review the results. After you determine how to best review
the results, you can define the input node numbering scheme. Based on the node numbering
scheme, you can then decide how to generate the model to take advantage of the various
rotate, duplicate, and include options.
For this example system, the core piping is modeled using node numbers from 1000 to 1999,
and the jacket is modeled using node numbers starting at 2000. Additionally, similar locations on
the two systems will have the same base node number, that is, nodes 1110 and 2110 describe
the same point on both the core and the jacket. Setting up the node numbers in this manner
enables one of the systems to be generated from the other, using either the duplicate or the
include options of the input preprocessor. You can also view the system individually in the plot
by the Range command and breaking the model at node 1999. The other advantage to this
numbering scheme is that when reviewing the output, you can immediately tell from the node
number whether the point in question belongs to the core or the jacket.
Although not necessary for a small system such as this, additional node number ranges can be
defined to differentiate parts of the model. To illustrate, the following additional constraints can
be placed on the node numbers. The ground level piping will have nodes in the 100-400 series,
while the second level piping will have nodes in the 500-900 series. For example, node 1110 will
be a core node at ground level and node 2550 will be a jacket node on the second level. To
indicate locations where external supports are applied to the system, node numbers will end in
5; all other points will be multiples of 10. Similar node numbering schemes can be used to
differentiate branches from headers, pipe from structural steel, and various line sizes. Starting
the modeling process with a clearly defined plan can ease both input verification and output
review. For example, consider reviewing the input for this system and finding a spring hanger at
node 1530. You can quickly recognize this as an error because the 1000 series nodes make up
the core piping and cannot use spring hangers. Additionally, support node numbering should
end with a 5.
Node Layout
The system as defined in the preceding figure consists of nine segments of piping. Each
segment is shown in the following figure with the node numbers assigned to the various points
for the core piping. Each segment is discussed individually.
Segment A - This segment runs from the pump to the first elbow. Because this section is at
ground level, the 100 series nodes are used. Because the pump acts as an anchor, the start
node of this segment ends in 5, so the pump is assigned node 1105. The length of the
segment requires an intermediate node point for a spider, so node 1110 is assigned 5-feet
from the pump. Nodes 1120 and 1115 are assigned to the elbow. The positive Y support is
not at node 1115 because 1115 is part of the core piping. The positive Y is applied at node
2115 (the jacket), so we assign the 5 to this node point.
Segment B - This segment is the six-foot vertical section, beginning with the elbow at node
1120. This section can be modeled by coding to the top elbow and assigning nodes 1500
and 1510. The 500 series nodes are used here because the 2nd level piping is now being
modeled.
Segment C - The first horizontal run in the 2nd level requires a node at mid-span to
accommodate a spring hanger (on the jacket). This mid-span node divides the segment into
two 9-foot lengths, which exceed the maximum spider spacing of 6-feet. Therefore, the
eighteen-foot span is divided into four elements, each one 4-feet, 6-inches. The nodes
assigned are 1520, 1525 (for the hanger location), and 1530. The segment is finished off
with the elbow modeled by nodes 1540 and 1550.
Segment D - This horizontal segment in the 2nd level is modeled using nodes 1560, 1570,
and nodes 1575 and 1580 at the elbow. The nodes 1560 and 1570 are for spiders, while
1575 is a hanger location
Segment E - This horizontal segment contains the valve. Nodes for this segment are 1590,
1600, 1610, and 1615. Node 1615 terminates the elbow and is also a hanger location. The
element from 1590 to 1600 should be declared rigid with a weight of 452 pounds. Starting
with the elbow at nodes 1610 through 1615, all of the elbows are modeled as individual
elements. This eases the subsequent coding of the jacket. The elbows in this part of the
model consist of two straight pieces of pipe, equal in length to the radius of the elbow.
Segment F -The third horizontal leg of the expansion loop is modeled using nodes 1620,
1630, 1640, and 1650.
Segment G -The last horizontal run of the 2nd level is modeled using nodes 1655, 1660,
and 1670. Node 1655 is a hanger location.
Segment H - The second vertical section of piping returns the system to ground level. The
only additional nodes required for this section are for the elbow at nodes 1130 and 1135.
Node 1135 is a positive Y location on the jacket.
Segment I - This is the last segment that terminates at the vessel nozzle. The nodes used
to model this segment are 1140, 1150, and 1155.
At this phase of the input, save the input file if you have not already done so. We also
recommend running the error checker at this time because the core piping model serves as the
basis for generating the jacket piping model. If any errors exist in the core, they are duplicated in
the jacket, thus doubling your correction efforts.
The additional data required to finish the model, such as allowable stresses, temperatures,
pressures, and so forth, are contained in the CAESAR II input file, which is delivered with the
software. This data is found in the [Installation Driver]\ProgramData\Intergraph Cas\CAESAR
II\5.30\Examples Jacket._a file.
To begin modeling the jacket, click Edit > List. The software opens the List Option dialog box,
which displays all of the applicable input data. Click the Elements tab to view a list of elements
and their associated delta coordinates as shown below:
For the first half of the jacket, the core piping is duplicated using the steps below. The duplicated
region starts at the pump and ends at the valve.
1. Click in the row for the element from 1105 to 1110.
2. Press Shift and click the row for the element from 1580 to 1590. This is the element just
before the valve.
The software highlights all rows between the two selections.
3. Right-click the highlighted list and select Duplicate.
4. In the Block Duplicate dialog box, click Identical.
5. Click At End of Input to place the duplicate block.
6. Specify 1000 for the node increment, and then click OK.
CAESAR II duplicates the block and increments all of the node numbers by 1000. This
results in a section of pipe identical to the pipe from 1105 to 1590 with node numbers from
2105 to 2590.
Three changes must be made to the new section of pipe to obtain the jacket piping. First, the
diameter and wall thickness must be changed to 12-inches, schedule 40. You can use the List
Editor to find the element from 2105 to 2110, and then type new values. Next, you must also
specify the following values: jacket temperature, jacket pressure, jacket insulation, and jacket
fluid weight. Finally, you must change all the jacket bend radii from long to short. The most
straightforward way to do this is to click the Bends tab on the List Options dialog box to open
the Bends list. Then, starting with the bend at node 2120, change the radius from Long to
12.0-inches. You must make this change to all of the remaining bends.
After the above changes have been made, the first half of the jacket is finished. A volume plot of
the system now shows the core piping overlaid by the jacket piping.
Although the two models are correctly positioned with respect to one another, they
are not connected. All you have done so far is duplicate several pipes. From the standpoint of
CAESAR II, there are simply two discontinuous systems in the same input file. The graphics
module plots discontinuous systems such that they all start from the same point, which is why
the jacket and core line up properly in this case.
The next step is to correctly connect the jacket to the core and apply any external restraints. The
connection between the jacket and the core piping must model the spiders that align the two in
the real system. These connections can be modeled in CAESAR II using restraints with
connecting nodes (CNodes).
The remaining three sections of jacket are modeled in exactly the same manner. The final step
in the modeling is to add the spring hangers at nodes 2615 and 2655 and the positive Y-restraint
at 2135. The completed model is shown in the following figure.
WRC 107
The following example illustrates a comprehensive local stress analysis of a vessel/nozzle using
WRC 107 and ASME Section VIII, Division 2 criteria.
To determine whether the WRC 107 Bulletin is appropriate for the computation of the local
stress state in the vessel due to external loading, review the geometry guidelines:
D = 120.0 in., T = 0.625 in., d = 12.75 in., t = 0.375 in.
d / D = 0.10625 < 0.33
Dm/ T = (D-T) /T = 191 > 50
In the example, both conditions are satisfied. The actual preparation of the WRC 107 calculation
input can now begin. One of the most important steps in the WRC 107 procedure is to identify
the correlation between the CAESAR II global coordinates and the WRC 107 local axes.
CAESAR II performs this conversion automatically. You must, however, identify the vectors
defining the vessel as well as the nozzle centerline. The following figure illustrates the definition
of the direction vectors of the vessel and the nozzle.
You can then replace the anchor with a WRC 297 local vessel flexibility model, and re-run the
job to see the range of loads and displacements that exist in the system around the vessel
nozzle. In either case, the restraint loads forces and moments can be obtained from the
CAESAR II Restraint report. These loads reflect the action of the piping on the vessel. The
following figure displays the restraint report of the rigid anchor model.
Figure 22: CAESAR II RESTRAINT REPORT: EX107 WRC 107 EXAMPLE PROBLEM
The total sustained axial load on the nozzle may not be reflected in the restraint report. A
pressure thrust load contributes an additional axial load to the nozzle. The pressure thrust force
always tends to push the nozzle away from the vessel. For example, with a pressure of 275 psi
over the inside area of the 12-inch pipe, the total P load becomes:
P = -26 - P(A)
= -26 - 275p (122)/4
= -31,128
If needed, the P load can be adjusted automatically for the input using the WRC 107/297
analysis module. To begin the analysis, click Analysis > Components > WRC
107(537)/297/PD5500 on the main window ribbon. The software first prompts you to create a
new WRC job and then prompts you to enter geometric data that describes the nozzle (Nozzle
Data tab) and the vessel (Vessel Data tab), followed by loadings data (Loads Data tab).
To do a WRC 297 calculation, click , and a new tab appears on the left side of the
dialog box.
You can enter up to three sets of loadings representing Sustained (SUS), Expansion (EXP), and
Occasional (OCC) load cases. CAESAR II automatically performs the stress calculation of each
of the load cases consecutively and then performs the WRC 107 stress summation routine to
compare the computed stress intensities against the stress allowables as required in Appendix 4
of ASME Section VIII, Division 2. The focus in the current example is only on the sustained and
thermal expansion cases. The loads are shown in the figure below. You can elect to leave any
boxes blank if they are not applicable. If a static analysis has been performed on the system you
are analyzing with WRC-107, CAESAR II can import the loads directly from the output file. To do
this, click Import Loads from Job for each load case. CAESAR II reads in the loads for the
nozzle node number that was specified on the Nozzle Data tab.
To run the analysis, click Local Stress Analysis on the WRC 107/297 toolbar. The
software opens an output dialog box and displays the processing results.
You can also click View Report Using Microsoft Word on the WRC 107/297
toolbar to perform the initial WRC 107 calculation and summation and send the results directly
to Microsoft™ Word .
After the input echo, the parameters extracted from the WRC 107 figures are printed to this
report. This step is similar to collecting the data by hand. These non-dimensional values are
combined with the nozzle loads to calculate the two normal and one shear stress. The stresses
are reported on the outer and inner vessel surfaces of the four points A, B, C and D located
around the nozzle. CAESAR II provides the normal and shear stresses and translates them into
stress intensities, which can be used for comparisons against material allowables. The outputs
of the stress computations are shown in the following examples. As the output shows, the
largest expansion stress intensity (117485 psi) occurs at the outer surface of point B (Bu).
1 E
180º Return Fitting-to-Fitting 90º Bends • 80 Elbows - Different Wall Thickness • 85
Evaluate pump discharge nozzle loads • 51
A Examples • 173
Existing Springs - No Design • 134
Anchors • 89 Expansion Joints • 147
Anchors with Displacements • 90
F
B
Flexible Anchors • 91
Ball Joints • 174 Flexible Anchors with Predefined
Bend Definition • 78 Displacements • 91
Bend Flexibility Factor • 86 Flexible Nozzle - WRC Bulletin 297 • 92
Bends • 78 Flexible Nozzle with Complete Vessel
Bi-Linear Restraints • 123 Model • 95
Flexible Nozzle with Predefined
C Displacements • 94
Check for errors • 34
Check the static load cases • 34 G
Closely-Spaced Mitered Bend • 82 Gimbal Joints • 162
Cold Spring • 137 Guides • 101
Combination Cases • 213
Conclusions • 47, 76
Configure the software • 12 H
Constant Effort Support Design • 132 Hanger Between Two Pipes • 140
Constant Effort Supports - No Design • 133 Hanger Design with Anchors in the Vicinity •
Convert Forces/Moments from CAESAR II 141
Global Coordinates to WRC 107 Local Hanger Design with Support Thermal
Axes • 257 Movement • 139
Core Piping Input • 250 Hanger Design with User-Specified
Operating Load • 143
D Hangers • 129
Harmonic Analysis (TABLE) • 187
Define the 6-inch bypass • 26 Harmonic Analysis of this System • 189
Define the first pipe element • 13 Hinged Joint • 155
Define the horizontal pipe run • 21 Horizontal Dummy Leg on Bends • 119
Define the vertical pipe run • 17 Horizontal Vessels • 183
Displacement Report • 212
Double-Acting Restraints • 99
Dual Gimbal • 165 I
Dynamic Analysis (NUREG9) • 233 Incorporate flexibilities at the vessel and
Dynamic Analysis of Independent Support nozzle intersection • 55
Earthquake Excitation (CRYNOS) • 214
Dynamic Analysis of Water Hammer Loads J
(HAMMER) • 200
Jacket Input (1st Half) • 250
Jacket Input (2nd Half) • 254
Jacketed Pipe • 176
Jacketed Piping (JACKET) • 246 Restraint between Vessel and Pipe Models
• 113
L Restraint Settlement • 109
Restraint/Force/Stress Reports • 212
Large Rotation Rods - Basic Model • 120 Restraints • 88
Large Rotation Rods - Chain Supports • 122 Restraints on a Bend at 30º and 60º • 115
Lift Off Spring Can • 145 Restraints on a Bend at 45º • 114
Limit Stops • 103 Results • 225
Review piping system loads on the pump •
M 48
Mass Participation Report • 211 Review static output reports for the new
Mitered Bends • 81 analysis • 59
Modeling Plan • 247 Review the graphical analysis results • 37
Modeling Spring Cans with Friction • 146 Review the model • 54
Multiple Can Design • 135 Review the piping input • 31
Review the piping system drawing • 11
Review the static output reports • 40
N Rigid Elements • 180
N1 Nozzle • 181 Rotational Directional Restraints with Gaps
N2 Nozzle • 182 • 106
Node Layout • 248 Run a new static analysis for WRC 297
Notes for Analyzing Water Hammer Loads • loads • 58
208 Run the static analysis • 36
NRC Example NUREG 9 • 234
NRC Example Problem 2A • 234
NRC Example Problem 2B • 237
S
NRC Example Problem 2C • 239 Simple Bellows with Pressure Thrust • 167
Simple Bottomed Out Spring • 144
Simple Hanger Design • 130
O Single and Double Flanged Bends or
Old Spring Redesign • 136 Stiffened Bends • 79
Omega Loop Modelling (OMEGA) • 241 Single Can Design • 131
Overview • 8 Single-Directional Restraint and Guide with
Gap and Predefined Displacement • 108
P Single-Directional Restraint with Predefined
Pipe and Hanger Supported from Vessel • Displacement • 107
138 Single-Directional Restraints • 100
Plastic Hinges • 125 Skewed Double-Acting Restraint with Gap •
Pressure-Balanced Tees and Elbows • 170 110
Skewed Single-Directional Restraint • 111
Slip Joint • 160
R Slotted Hinge Joint - Comprehensive Model
Redesign the piping system • 64 • 158
Reducers • 173 Slotted Hinge Joint - Simple Model • 156
Re-evaluate pump discharge nozzle loads • Solution Summary • 213
62 Static Analysis Output Listing • 41
Relief Valve Example Problem Setup • 192 Static Snubbers • 125
Relief Valve Loading Output • 196 Structural Analysis (FRAME) • 226
Relief Valve Loads (RELIEF) • 191 Sway Brace Assemblies • 126
Rerun the static analysis • 72
Restraint between Two Pipes Using
CNodes • 112
T
Tied Bellows - Simple vs. Complex Model •
159
Tied Bellows Expansion Joint - Complex
Model • 163
Tied Bellows Expansion Joint - Simple
Model • 151
Tutorial A - Create a typical piping system •
9
Tutorial B - Check equipment and redesign
a piping system • 48
U
Universal Expansion Joints - Simple Model
• 147
Universal Joint - Comprehensive Tie Rod •
171
Universal Joint with Lateral Controls Stops -
Comprehensive Tie Rod Model • 154
V
Vertical Dummy Leg on Bends • 115
Vertical Leg Attachment Angle • 119
Vertical Vessels • 178
Vessel • 180
Vessel Modeled as Pipe • 185
Vessel Skirt • 179
W
Water Hammer Loading Output • 211
Widely-Spaced Mitered Bend • 83
Windows • 105
WRC 107 • 256