Stress Intensification Factor (SIF) for Thin walled Fittings

when the pipe diameter to thickness (D/t) ratio becomes more than 100, Caesar II will give warning
as “ AT INTERSECTION: XXX the fitting has a D/t ratio greater than 100. SIF computations for
this fitting may be invalid” This warning message is generated for all Bend and Intersections in
the pipe where the D/t ratio is more than 100. This is due to the ASME Piping code limits the D/t
ratio less than 100.

These normally happen for very large size low-pressure systems. Due to low design pressure (of
the order of 1 bar to 3 bar) calculated thickness is less. For example, consider a flare line of 42
inch (or 48 inches) NPS with 3 bar design pressure. The selected thickness is STD wall thickness
i.e., 9.525 mm. So the Diameter to thickness ratio is more than 100.
 Stress Intensification Factor (SIF) for Thin walled Fittings

Size OD(mm) Thk(mm) D/t

36" 914 7.92 115
38" 965 9.53 101
40" 1016 9.53 107
42" 1067 9.53 112

In such case either of the following shall be followed,

• SIF shall be evaluated based on some FEA tool.

• Multiply the Caesar calculated SIF at intersections by 2.0-3.0 and input the same
manually at all three node points (Branch and header) as a conservative approach.

• Instead STD thickness, “XS” thickness shall be used.

Same way the Impact of Pressure on SIF calculation for thin walled Elbow and Tee shall be
taken care as per Notes of 6 in Table D 300.