Caesar II Static Training

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CADWorx & Analysis Solutions
CAESAR II Statics Training
CAESAR II
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CAESAR II Version 2011 - Statics Training
Duration: 5 Days
Prepared by: Chris Bradshaw
Copyright 2011 Intergraph CADWorx & Analysis Solutions
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UnTnrrv rti i CAESAR II Statics Training
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IIN I LRVJIWTI Introduction
i
Contents
Introduction 6
Interface 6
Default Data Directory 6

Units 7
Create Custom Units File 7
F = Kx Example 9
Model Input 12
Load Case Editor 16
Hand Calculation 18
Output Processor 19
Axial 21
Theory and Development of Pipe Stress Requirements 25
Basic Stress Concepts 25
Example 30
3 D State of Stress in the Pipe Wall 33
Failure Theories 36
Maximum Stress Intensity Criterion 38
Code Stress Equations 40

B31.1 Power Piping 40
Pipe 1 42
Input Model 43
Error Checking 52
Review Load Cases 54
Review Results 55
Supt 01 64
Locating Supports 65
Adding Supports to Model 69
Analyse 75
Fix Model 80
Place Spring Hangers 87
Flange Analysis 92
Inline Analysis 92
Kellogg Equivalent Pressure Method 94

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Introduction
NC-3658.3 Method 96
Flange Analysis Module 101
Turbo 108
Model Inlet 109
Combine Models 114

NEMA SM23 116
Manifold 133
API 610 Analysis 144
Tutor 152
Boundary Conditions 154
API 610 Analysis 160

Fix Model - Parti 163
Include WRC 297 flexibilities 163
Review Results 165
Fix Model - Part 2 167

Build Steel Structure 168
Combine Pipe and Steel models 178
Review Results 181
Loop Optimisation Wizard 185
Model the Expansion Joint Assembly 194

Document the Analysis 198
Custom Reports 198
Filters 202
Generate Report 203
ISOGEN Stress Isometrics 206
Cool Hz0 - FRP Piping 218

Basics of Fibreglass Piping Analysis 219
CAESAR ITs Orthotropic Model for Piping Systems 222
Requirements of the ISO 14692 Code 223
Allowable Stress Data for this Model 226
Configuration Options for FRP Piping: 228
Model the system 230

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E R
" s IaSi
Load Case Setup 237
Review Results 237

Solving Expansion Problems 238
Static Seismic Using the ASCE 7-05: 238
Inertial Loads 238
Seismic Data Input 243
Load Case Setup 247
Review Results 249
Gas Transmission Pipeline - Buried Pipe 253

B31.8 Design Code 254
Modelling the system 254
Material Database 259

Buried Pipe Modeller 262
Restraint Parameters 262

American Lifelines Alliance Clay Model 263
American Lifelines Alliance sand model: 265
Meshing Parameters 266
Virtual Anchor Length ( VAL): 268
Bury Pipe 269
Load Case Setup 274

Results Review 275
Fatigue 276
Setting up the Fatigue Load cases 276
Riser 279
Modelling 280
Injection Line 281
Product Line 285
Jacket 286
Hydrodynamic Theory 289
B31.4 Code Requirements 290

Hydrodynamic Input 291
Wave Solution 292

Hydrodynamic Coefficients 297
Wind Loading 299

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Introduction
Load Case Setup . 302

Analysis . 303
SUPT01- Water Hammer .305
Edit the Model . 306
Determine the Load 307

Define the Occasion Load 308
Load Case Setup 308
Check the Results 309

Reset the Load Cases 309
Check Results 310
Correct model 311

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Introduction
Introduction
CAESAR II is pipe stress analysis software which uses beam theory to evaluate piping systems to
.
numerous international standards CAESAR II is not Finite Element Analysis (FEA) software, but
instead uses a stick model built up of elements connected by nodes.
This course will introduce CAESAR II and demonstrate various modelling and analysis methods in
order to evaluate and correct piping systems.
Interface
When starting CAESAR II, the Main Window appears. This is the window where all tasks are started
from. This includes opening/creating an input file, reviewing Load Cases, reviewing results or
accessing any auxiliary modules such as WRC 107/297 processor or the ISOGEN stress isometrics
module. All modules open up in their own separate window .
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When opening a new file, the file will open, but you will return to the Main Window You can then .
choose to go to the Input processor, Output processor or the results for this file.
These modules (and other auxiliary modules) and their interfaces will be introduced as they occur
throughout the training.
Default Data Directory

CAESAR II has the option to specify the default working directory - that is all files working with will
be saved/opened from this default location. Of course it is still possible to navigate using windows
explorer functions, this setting is just the default location when selecting New/Open.
Select File > Set Default Data Directory from the CAESAR II Main window
% A
Hie
! Set Default Data Directory
D New Ctrl+N
ID Open... Ctrl+O
Recent Piping Hies >
Recent Structural Hies
Exit

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Introduction
Click on the ellipsis button at the end of the text field and browse to E:\Training\CAESAR ll\Exercises
M fault Da
I E:\Training\CAESAR n\Exercises
fP|
OK Cancel Help Examples
Units
.
CAESAR II performs all internal calculations in English units To enable the entry and review of data in
alternative units (such as SI), units files are used by CAESAR II. These units files simply convert the
internal CAESAR II English units to the user's preferred unit. Each CAESAR II file ( referred to as a Job
File ) uses a particular units file which is specified on creation of the job. Files can be converted
from one units file to another if required. The units files have the extension *.FIL and are located in
.
the CAESAR II System directory, or in the same directory as the job file The file to use is specified in
the Configuration file.
Create Custom Units File

Throughout this course, we wish to use specific units for various parameters such as Pressure,
.
Density etc As such we require a units file which is different to the supplied default files. So we will
create our own CAESAR II units file.
Select Tool > Make Units Files from the Main Window
Tools IHE
D o p e Configure/Setup
Make Units files
k
This allows the creation of new units files, or the review of existing units files, useful if you receive a
units file from a colleague and wish to check the units in use in the file.
Choose to Create New Units File and for the template file to use as a start point, select *MM.FIL.
Give the new file a name and click View/Edit file .

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CADWora & Analysis Solutions
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Existing Rle to Review

Review Existing Units Files
Existing Rle to Start From:
=5
Create a New Units Rle 1MMRL
New Units Rle Name

TRAIN
View / Edit Rle Cancel
In the Units File dialogue box, change the following units from the MM defaults:
Stress N/ sq .mm.
Pressure bars
Elastic Modulus -> N/ sq.mm.
Pipe Density -> kg/cu.m.
Insul. Density >- kg/cu.m.
Fluid density -> kg/cu.m.
Transl. Stiffness -> N/ mm
Uniform Load -> N/ mm
Ensure Nominals is set to ON. This allows the entry of pipe nominal sizes and schedules into the
input, which will be converted to actual diameters and wall thicknesses (e . g. enter 4 into the
diameter field and CAESAR II will convert this to 114.3mm).
Give the file a label as well to easily identify the file.
f CAFSAR II
ITEM
Ufiitf File Maintenance
Internal Units Constant User Units
_ User Units
Length inches * 25 4 '

j mm -j Fluid Den lbs /cu in * 27680 * kg/ cu m. *
Force pounds 4 4480 ]-: * Transl Stiff lbs /in " 17512
-
N /mm
-J
-
Mass dynamics pounds * 0 4536 ' 9 1 11 Pol SfrfT -
in fb7deo
" !
Nm /deq
i
-
Moment input
Moment-output
in -lb
-lb
* 011298
29 B M
Nm
Nm
; ([ unit Load
teloati
Ib /m
g 1
*
* 1 7512e 1
- tuuuu
- z
- '-gs TTI
-
in
I Stress lbs / sq m * 0 0068946 M [N. /sqmm Wind Load lbs / sq in * 6 8946 -- KPa
1 Temp Scale
I Pressure psig
~
degree?F * ' & 5SST
0 068946 .'
I , L . Elevation
fcmpd Lng
inches
inches
0254
* 25 4
- m
mm
~
1 Elastic Modulus 00068946 [ * [N / sqmm Ipiameter inches * 25 4000 mm F
: lbs / sq in
YJ '
*
'
JNAV r Phpe Density
1
Insulation Den
Units File Label

ibs /artn
lbs /coin
1 WW
[ 27680
TRAINING
pI
' kg/cum
kg/cu m
b1
*
Thickness
Nominals
k
inches * 25 4000
c .
|mm
ON
EE
-]
I QK / Sove ] Cancel
/
& Copyright 2011 Intergraph CADWorx & Analysis Solutions
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Introduction
F = K,Y Example
As CAESAR II uses a stick model, and beam theory, it is easy to prove this using a simple cantilever
example. This example will introduce the basic modelling methods in CAESAR II and introduce the
Input Spread Sheet, Load Case editor and the Output Processor. In addition, we can check the
CAESAR II results against some simple hand calculations.
.
CAESAR II calculates forces using F = Kx Using the example below, we will create a simple
cantilever model, fixed at one end, and apply a displacement of 2 mm at the other end. We can then
calculate the force required to generate this 2 mm displacement - and see this in the results.
F
v
d = 2 mm
First we will create the model in CAESAR II.
Create a new file in CAESAR II, called FKLateral
Hie
Set Default Data Directory
J
U ,Nev
,,ev;
[\ Ctrl+N
& Open?:. Ctr +O
New Job Name S
Enter the name for the NEW job file:

FKLateral
9> Piping Input Structural Input

Note, structural files should have different names from
piping files, even if they are to be combined for analysis.
Enter the data directory

D:\Training\CAESAR n\Exercises
Jd
[ 2K Help Cancel
After creating the new job file, the first time it has opened, the units will be displayed to the user for
confirmation. You will notice that the units file displayed here for our file is English ( CAESAR II
default units) not the units file we have just created. By default, CAESAR II uses the units file set in
the Configuration/Setup as the default file for new jobs (and also as the units to use to display the
output results ).

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CADWont & Analysis Solutions
Introduction
Review Current Units

ITEM Internal Units Constant User Units ITEM nternal Units Constant User Units
Length
Force
inches
pounds
1
1
-- in.
lb.
Fluid Den. Ibs./cu in.
Transl. Stiff. lbs. /in.
1
1
lb , / cu .in.
lb , /in.
Mass-dynamics pounds
-
Moment input -
in. lb.
1
1
-
- ..
Ibm
in.lb.
Roll. Stiff.
Unif. Load
in-lb / deg
Ib. /in.
1
1
in. lb , / deg
Ib. /in.
Moment-output in.Hb. 00833333

- ./ . .
ft lb G Load g's 1 g's
Stress Ibs. / sq in. 1

-F Ib sq in Wind Load Ibs. / sq.in. 144 lb . / sq . ft.
.- / . .
Temp Scale degrees F 1 Elevation inches 00633333 A.
Pressure psig 1 Ib sq in Cmpd Lng inches 0.0833333 ft
Elastic Modulus Ibs. / sq.in. 1

- // .. ..
Ib sq in Diameter inches 1 in.
Pipe Density Ibs./cu.in. 1

- lb cu in Thickness inches 1 in.
Insulation Den. Ibs./cu.in. 1

- Ib./ cu.in. Nominals ON
Units File Label: ENGUSH
I 0K I
Click OK on the units review screen and the input spread sheet will open. To confirm/check the
units, hover over any field in the input - the units used in this field will be displayed in the tooltips.
For example, we changed the pressure units to bars, but the pressure field displays the units as
Ib./sq.in.
Temp 2
Temp 3
Pressure 1
Pressure 2 ffb./ sq.in.|
Hydro Press
Close the input screen - we will change the units and return to the input with the correct units
displayed.
In the CAESAR II main window select Tools > Configure /Setup
pH CAESAR II [ D:\TRAINING\CAESARll\FKAXIAL]
-
__
| File Input Analysis Output Diagnostics ESL Viev t: W!
D e I ISLB . Configure/ Setup

Make Units files
In the window which appears, select Database Definitions from the categories tree on the left.
Configuration
Computational Control
Datab as eiDlSnitions
CDDD .... . 4U
Now change the Units File Name setting to the units file just created.
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Introduction
3 Databases
Alternate CAESAR II Distributed Data Path
Default Sprinq Hanger Table Anvil
Expansion Joints FLEXPATH JHD
Load Case Template LOAD TPL
Piping Size Specification ANSI
Structural Database AISC89
Units File Name TRA1N.FIL
User Material Database Filename ENGLISH FIL
Valve/Flange Files Location BAR FIL
Valves and Flanges DEUTSCH FIL
3 ODBC Settings
Append re-runs to existing data FRANCE FIL
Enable data export to ODBC compliant databases I'MMFIL
ODBC Database File Name
SI FIL
TUVFIL
Save and exit.
C P
: " CAESAR II Co
J Reset All -
N| Save and Exit P
B Configuration
Return to the Piping Input. Again, the units file to be used will be displayed - this should now be
your custom units file.
C1I CAESAR II - [D:\TRAIf

i File input Analysis Outpu
1Da E
Piping Input
Verify that the correct units are in use via the tooltips
Temp 1
Temp 2;
C Temp 3
Pressure 1 tv
Pressure 2 pars I
tydro Press.

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Introduction
Model Input
We will now create the simple cantilever model and apply a 2mm displacement at the free end.
The model will be as follows:
One element 10m in length going from node 10 to node 20 in the X direction, anchored at one end .
8 pipe with Standard wall thickness.
/
/
10 20
/
10m
-H
Y
/
The input spread sheet will have defaulted to nodes 10 to 20, so simply enter 10000 in the DX field.
We are in mm units already.
Enter the pipe diameter and wall thickness - this is 8 NS and STD wall thickness. As we have
nominals set to ON, simply type in 8 in the diameter and hit enter. The actual OD for 8 pipe will
.
be inserted Repeat for the wall thickness, simply type in S and press enter.

From: 10

DX: 10000 000 mm
DY:
DZ:
0 Offsets

Diameter 219 0750
Wt/Sch 81700
Now we must fill in the pipe properties. We need to know the material properties to carry out the
analysis. Select A106 - B from the list of materials. Notice that all materials have a number to
identify it, you can simply type in the material number here - in the case of A106-B this is 106.
Selecting the material will fill in the Elastic modulus and Poisson ratio and various material
allowables under the Allowable Stress area, depending on the design code selected ( B31.3 default).

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Introduction
Material (106)A1O6 B
0 Allowable Stress
>>
Elastic Modulus (C) 2.0339E + 008
Elastic Modulus (H1): [2.0340E+008

Elastic Modulus (H2) 2 Q 339E *008
'
Elastic Modulus (H3)' 2.0339E + 008
Poisson's Ratio' 0.2920
Code: 031.3 E
SC 137.892
SHI 137.892 FI:

SH2. 137.892 F2
SH3: 137.892 F3
SH4: 137.892 FA
That is our pipe itself. We now need to anchor it at one end ( node 10) and apply a displacement at
the other end (node 20).
Place the anchor by double clicking the Restraints check box. All the check boxes shown in the
middle column on the spread sheet must be double clicked to check/uncheck.
0Restraints |j [Displacements
"nHahgers 1
0 Flange Checks
Nozzle Flex. Nozzle Lmt Check
To define a restraint you must specify a minimum of the node that the restraint will be attached to,
plus the type of restraint. Press FI for more information on the different restraint types. We need
an anchor, so select ANC and locate it at node 10.
Node: 10 CNode:
Type: ANC 1 Gap:

Stif: Mu:
Now we will apply the 2mm displacement at the opposite end. Double click the Displacements
check box to apply a displacement.
0 Restraints |[ 0Displacements
Hangers U flange unecks
Nozzle Flex. C Nozzle Lmt Check
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Introduction
Specify the displacement at node 20, and specify a 2mm displacement downwards in the Y direction
- i.e. enter -2 in the DY row.
Leave the remaining rows empty - do not specify 0. Specifying 0 fixes the node in the specified
direction. Entering 0 in each row would be the same as an anchor. Leaving the values blank leaves
the remaining directions free.
Node 1 20
Vector T| Vector 2 Vector 3 Vector

DX
DY -2 0000
DZ
RX |
RY
RZ
!
SH >
Finally to complete the analysis we must specify a design temperature and pressure In our case.
these are not really relevant as we are only concerned with displacement, so just enter 21C in T1
and lbar in PI fields.

Temp 1 21.0000
Temp 2
Temp 3
Pressure 1 1 0000
Pressure 2.
Hydro Press
The file can now be analysed .

Before analysis the input must be error checked in order to identify any issues which may prevent
the analysis running (such as specifying both an anchor and an applied displacement at the same
point), or anything which may provide incorrect results (such as Stress Intensification factors not
present at a geometric intersection).
Run the error checker to check the model.
is ar & &
s ?
i * * *n
Start Run
Run the Error Checker

'tings: 0
You should see only one note in the error checker report - the C of G. This can be useful for
identifying problems such as incorrect densities applied - giving an incorrect weight for example.

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Introduction
Errors and Warnings

I Errors: 0 Warnings: 0 INotes: 1
Message Element/
Message Type Message Text
Number Node Number
1 NOTE
CENTER OF GRAVITY REPORT

Total Wght X eg Y eg Z eg
N. mm. mm. mm.
Pipe 4162.5 5000.0 0.0 0.0
Insulation 0.0 0.0 0.0 0.0
Refractory 0.0 0.0 0.0 0.0
Fluid 0.0 0.0 0.0 0.0
Pipe+Ins+Rfrty 4162.5 5000.0 0.0 0.0
Pipe+Fluid 4162.5 5000.0 0.0 0.0
Pipe+Ins+Rfrty+Fld 4162.5 5000.0 0.0 0. D
If you receive anything other than this C of G, review the model for any issues. A common error on
this exercise is the following:
Errors and Warnings

IErrors: 1 Warnings: 0 Notes: 0
Message Element/
Number Node Number
1 ERROR 57E 10-20 At node 10 there is a DISPLACEMENT and a
RESTRAINT specified . This results in a numerically
overspecified boundary condition. The user should
either give the displacements of the point, or
restrain the point, but not both. If modelling
initial thermal movements at a restraint, define
some unique connecting node for the restraint, and
specify the displacement for the connecting node .
This indicates that the displacement and the anchor have been specified at the same location. Check
that the Anchor is specified at Node 10 and the displacement is specified at Node 20.

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Introduction
Load Case Editor

Once the error check is successful, we can create load cases to analyse the system. Access the load
case editor. This button is only available after a successful error check.
|j @ a g - m .- i
-
Edit Static Load Cases

s
i Start Static Analysis
rnings: 0 Note
The load case editor will be shown.

x
P Static Analysis - [D:\TRAININJGACAESAR II\FKAX!Al!] " '
: File Edit INI3GR)SPH'

[la a ia _o _
Load Case Editor Load Case Options ; Wind Loads j Wave Loads
Loads Defined in Input Load Cases | Stress Type | Recommend

W - Weight L1 W+D1+T1+P1 OPE
-
D1 Displcmnt Case #1 L2 W+P1
L1-L2
SUS
Load Cycle
L3 EXP *
P1 - Pressure Case #1
WW - Water Filled Weight Import Load Cases
-
WNC Weight no contents
The default load cases are the Operating, Sustained and Expansion cases, as required by the design
codes such as B31.3. Remove all these load cases, as we are only concerned with the displacement.
wmm , delete Entry

Load Case Editor | Load Case Options wind L [
Add one new row.
Q a &
*
Load Case E Add Entry j ,
Into the load case we can add any of the loads defined in the input into the load case. As we are
only concerned with the displacement, drag in D1- Displacement Case #1into the LI row.

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"
Introduction
Loads Defined in Input Load Cases j Stre

W - Weight L1
c D1 - Displcmni Ca ~#1
T1 - 1 hermal Case #1
J Displcmnt Case.#, j
WW - Waler Riled Weight
WNC - Weightno contents
Also select the stress type as SUS(tained).
Load Cases | Stress Type |

L1 D1 sus|
The analysis will now take into account only the displacement reaction.
Before we analyse the piping system, let us first perform the hand calculation in order to check.

IlMItKijKAPH CAESAR II Statics Training
Introduction
Hand Calculation
As we know, F = Kx
F - Force
K = Stiffness
x = Displacement
The stiffness K is
3El
K=
ir
I= ( D 4 - d* ) ; Where D = Pipe OD and d = Pipe ID
E being Modulus of Elasticity and L being the length.
So if we wish to know what force is required to displace the cantilever 2mm, we can calculate this
quite easily.
E = 203 A: 103 N / mm2
L = 10,000mm
D = 219.08mm
d 202.72 mm
3 x 203 E 3 x (219.084 - 202.724)

(10E3) 3
K = 18.379 N / mm
So for a 2mm displacement, the force required is
F = Kx
F = 18.379 x 2
F = 36.758 N

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CADWorx0 & Analysis Solutions
Introduction
Output Processor
Back in CAESAR II, run the analysis by clicking on the Running Man icon from within the load case
editor .
F Static Analysis - [D:\TRAMNG\CAESA

j File Edit
a<
iel- aa
;
ift
e
| Load Case Editor [ JRun the Analysis ) ) wind Lo
You will see the following message explaining that certain loads have been defined in the model but
are not included in any of the load cases to be analysed - this is OK in our case, but can serve as a
useful warning if you have may loads/load cases defined. Select OK as is...Continue and click OK to
analyse.
irnTrrr i
The following loads were defined in the input and have NOT been used
in any of the load cases and will NOTbe considered in the analysis (i e
have they will have no effect): W T1 P1 WNC VvW
Return to Load Case Definitions

OK as ls...continue
| OK
Once the analysis is complete, the Output Processor will be shown. We can view various results for
any load case from here, plus general model reports such as the Input Echo. These reports can be
viewed on screen, or output to Word/Excel/Text or straight to a printer.
In addition Custom report templates can be created, and any available report can be selected and
added to the Output viewer Wizard, and exported/viewed to create/view a comprehensive report
very quickly.
For now we will just check the displacement at node 20 to verify that it is 2mm, and the force at
node 20 to check against out hand calculation.
Select the load case (SUS) D1 and the Displacements standard report and click to show on screen:
Pit Static Output Processor - [ D:\TRAINING\CAESARII\FKAXIAL]
j File View Filters Options PiotOpticr,.- CrtVirv: Show Window
IDB n a a g a esj
! - Sli - + - &
\ View Reports
,-aandawi.Waportt-
IHSHttCBSliTAnSlyzstf
1(SUS) D1 } | .
|iDitriKren 3iifc)
D]EKimiEffiT 1
Restraints Extended

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Introduction
The DY at Node 20 is -2mm, as we specified.
(l)Displacements
CAESAR II 2011 SP1 Ver.5.30.01, (Build 1102281
Job: D:\TRAINING\CAESAR II\FKAXIAL
Licensed To: Seat ID #51
DISPLACEMENTS REPORT: Nodal Movements
CASE 1 (SUS) D1
DX DY DZ
NODE
mm. mm. mm.
10 0.000 -0 . 0 0 0 0.000
20 0.000 -2 . 0 0 0 0.000
S
'
Now to check the force at node 20; view the Global Element Forces report.
Standard Reports
Displacements
Restraints
Restraints Extended
Local Restraints
Restraint Summary
Restraint Summary Extended
Nozzle Check
Flange Peq
Flange NC-36583
j
Global Element Forces Extended
Local Element Forces
Qimrrnt'
(l)Global Element forces

GLOBAL ELEMENT FORCES REPORT: Forces on Eleme
CASE 1 (SUS) D1
// \
NODE
FX FV FZ
N. N. N.
10 0 37 0
20 0
V -37 J 0
37 N as we calculated.

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INTERGRAPH
Introduction
Axial
We can repeat this exercise for axial forces. This is a simple change in the model changing the
displacement from the Y to the X direction.
Node 1 20
Vector11 factor 21 Vector 3 Vector

[ DX 2.0000
. DY ,!
DZ 1
RX
RY
RZ
-s .
The analysis can be quickly re -run in cases where a change such as this has been made by using the
Batch Run Double Running Man icon. This will run the error checker followed immediately by the
analysis ( providing there are no Errors).
- FET
eJjB a
-3 T*
<h
-
iU 0 tUgj .m U
<s> 4
ft
'
1* Batch Run tfji e
ut Error check and analyze
> > job
1 Rprlur
The force should be as follows:
We are still using F = Kx, but we are using the Axial stiffness .
AE
K =-
A = cross Sectional area (mm2)
E = modulus of elasticity (N / mm2)
L = Pipe Length
D2 d2
A= n -n
2 2
A = j(219.08z - 202.722)
A = 5419.76 mm2
Therefore:
5419.76 x 203E3
K~
(10E3)
K = 110,021 N/mm
So for an axial extension of 2mm, the force required is

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CADWorx* & Analysis Solutions
Introduction
F = Kx
F = 110,021 x 2
F = 220, 043 N
The CAESAR II results, Global Element forces report should verify this:
(l)Global Element Forces

GLOBAL ELEMENT FORCES REPORT: Forces on Eleir
CASE 1 (SUS) D1
FX
NODE
N.
10 -220423
20 220423

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INTERGRAPH
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CADWarx & Analysis Solutions
Introduction
The forces calculated such as in the previous example produce bending moments throughout the
.
piping system Bending moment is produced when a Force is applied at a distance - MB = F x L
Once the bending moment has been calculated beam theory is used in order to calculate the stress
at this point.
a _ M
~
y T
a = Stress ( N / mm 2 )
M = Bending Moment (Nmm)
Y = Distance from Neutral axis to outer fibre of beam ( mm )

I = Moment of Inertia ( mm4 )
a M . M y
-= rearranges to a = - j-
- is the section modulus Z. So this reduces further to

y
The stresses are calculated using this basic theory and compared to the allowable stresses in the
design codes. CAESAR II has many design codes available, all of which have evolved separately over
time, thus the way the stresses are calculated for each specific code are slightly different. However,
looking at one of the most common piping codes - B31.3 - it can be seen that the equations used
are based on the basic bending as detailed above.
B31.3 Chemical Plant and Petroleum Refinery Piping
Sustained:
Fax . [ ( UMi )2 + ( ioM,) 2 ] 1 2 , P d 0

SI ~ + AZ z '
+ 7 55h
Expansion:
[ OjAfj) 2 + doMp )2 + 4My 2 ] 1

'
2
,
SA = f ( 1.25Sc + 1.25Sh - 5 )

INTERGRAPH
*
Introduction
.
As can be seen, the equations essentially use bending stress M/Z The equations are a little more
complicated than the basic cantilever example for the following reasons:
To address piping systems in 3 dimensions

To address areas in a piping system where particular geometry/components, such as at a
branch connection or a bend, can increase the stress, and therefore the likelihood of failure.
.
At these points, the stress is increased by a Stress Intensification Factor (SIF) known as / The
design codes contain formulae to calculate these SIFs.
Stresses can also be caused by Pressure and Axial Forces
The Stresses are categorised into Sustained, Expansion and Occasional, as detailed below.
Sustained Stress: This is primary stresses caused by primary loadings such as the weight and
pressure of the piping system.
Expansion Stress: Expansion stresses are secondary stresses caused by secondary loadings such as
the thermal expansion and applied displacements.
Occasional Stress : Combines sustained stresses with those produced by an occasional loading such
as earthquake of relief valve operation. As these are occasional loads, the allowable can be
increased by a scalability factor, k . k is usually dependant of the duration or frequency of the
occasional load.

iNTbKUKAPH
*
Theory and Development of Pipe Stress Requirements

Basic Stress Concepts
Normal Stresses: Normal stresses are those acting in a direction normal to the face of the crystal
structure of the material, and may either be tensile or compressive in nature. In fact in piping,
normal stresses tend more to be in tension due to the predominant nature of internal pressure as a
load case. Normal stresses may be applied in more than one direction, and may develop from a
.
number of different types of loads For a piping system these are:
Longitudinal Stress: Longitudinal or axial stress is the normal stress acting along the axis of the pipe.
This may be caused by an internal force acting axially in the pipe .
S,>
Where:
SL = Longitudinal Stress
= Internal axial force acting on cross section
A = Cross sectional area of pipe
n( d 02 ~ di 2 )
d 0 = Outer diameter
d; = Inner diameter

iNTtnbnAPH
*
A specific instance of longitudinal stress is that due to internal pressure:
sL
SL = P Ail A
m Internal Pressure
SL
P = Design pressure
Ai = Internal area of pipe
2
At = 7tdi /4
Replacing the terms for the internal and metal areas of the pipe, the previous equation may be
written as
SL = Pdi
2
/ ( d 02 - dh Or:
2
SL = Pd / ( 4dt )
For convenience the longitudinal pressure stress is often conservatively approximated as
Pd
5 =

Bending Stress: Another component of axial normal stress is bending stress. Bending stress is zero
at the neutral axis of the pipe and varies linearly across the cross- section from the maximum
compressive outer fibre to the maximum tensile outer fibre. Calculating the stress as linearly
proportional to the distance from the neutral axis:
Variation in Bending Stress Thru

Cross Section
SL = Mbc / I
Where:
Mb = Bending moment acting on cross section

c = Distance of point of interest from neutral axis of cross section
/ = Moment of inertial of cross section
/ = 7r (d 04 - d;4) / 64

IlMItKUKAPH
The maximum bending stress occurs where c is highest - the maximum value c can be is equal to the
radius of the pipe.
Smax = Mf, R0 / I - Mi, 12

Where:
R0 = Outer radius of pipe.
Z = Section modulus of pipe
Z = 1 / R0
Summing all components of longitudinal normal stress (for axial and bending):
F _ , Pd , Mt
=
A 41 Z
Hoop Stress: Hoop stress is another of the normal stresses present in the pipe and is caused by
internal pressure. This stress acts in a direction parallel to the pipe circumference.
The magnitude of the hoop stress varies through the pipe wall and can be calculated by Lame's
equation as:
SH = P
Where:
SH = Hoop stress due to pressure

r,j = Inner radius of pipe
r0 = Outer Radius of pipe
r = Radial position where stress is being considered
The hoop stress can be approximated conservatively for thin- wall cylinders by assuming that the
pressure force applied over an arbitrary length of pipe, I is resisted uniformly by the pipe wall over
that same arbitrary length.

INTERGRAPH
"
c Pdil
SH 2tl
Or conservatively
Radial Stress: Radial Stress is the third normal stress present in the pipe wall. It acts in the third
orthogonal direction - parallel to the pipe radius. Radial stress is caused by internal pressure and
varies between a stress equal to the internal pressure at the pipe's inner surface, and a stress equal
the atmospheric pressure at the pipe's external surface. Assuming that there is no external
pressure, radial stress is calculated as :
sR = = o
SR = P ( ri 2 - ~T ) / (ro - n2)
2
Where
SR = Radial stress due to pressure

Note that radial stress is zero at the outer radius of the pipe, where the bending stresses are
.
maximised For this reason, this stress component has traditionally been ignored during the stress
calculations.
Shear Stresses: Shear Stresses are applied in a direction parallel to the face of the plane of the
crystal structure of the material and tend to cause adjacent planes of the crystal to slip against each
other. Shear stresses may be caused by more than one type of applied load. For example, shear
stress may be caused by shear forces acting on the cross section.
Shear Dislr bulion

Profile

INTERGRAPH
_ VQ
Tmax ~

Where:
Tmax = Maximum shear stress
V = shear force
Q = shear form factor. Dimensionless quantity (1.333 for solid circular section)
These shear stresses are distributed such that they are at the maximum at the neutral axis of the
pipe and zero at the maximum distance from the neutral axis. Since this is the opposite of the case
with bending stresses and since these Shear stresses are usually small, shear stresses due to forces
are traditionally neglected during pipe stress analysis.
Shear Stresses may also be caused by torsional loads .
1
r
Tmax = MTC / R
Where:
MT = Internal torsional moment acting on cross-section

c = distance of point of interest from torsional centre (intersection of neutral axes) or cross section
R = torsional resistance of cross section
R = 2I
R '
_ njdg - d * ) ,
32
.
Maximum torsional stress occurs where c is maximised Again at the outer radius .
. MT
TMAX = MT r0 / 21 =
Summing the individual components of the shear stress, the maximum shear stress acting on the
pipe cross section is:
_
-
VQ Mr
Tmax
A
+ 2Z

IWTERGRAPH
As noted above, a number of the stress components described above have been neglected for
.
convenience during calculation of pipe stresses Most piping codes require stresses to be calculated
using some form of the following equations:
Longitudinal Stress:
__ Mb
SL A 4t
i
Z
Mj
Shear Stress: T
2 F
Pdg
Hoop Stress:
2t
Example
This example calculation illustrates for a 6 nominal diameter, standard schedule pipe (assuming the
piping loads are known):
Cross sectional properties
Outside diameter d= 168.3mm
Mean thickness tm = 7.112mm

Inside diameter d( = d0 (2 x tm)
d; 154.076mm
Cross sectional Area A= ( d 02 - di 2 )
A= (l68.32 - 154.0512 )
A = 3.601 x 103 mm2
Moment of Inertia 1= (d04 - dj 4 )

/= (168.34 - 154.0514 )
1 = 1.171 x 107mm4
Section Modulus Z=
( d 0 / 2)
_ 1.171 xio7
~
(168.3 / 2)
Z = 1.392 x 105 mm3

INTERGRAPH
Theory and Development of Pipe Stress Requirements - - '
Piping loads
Bending Moment Mb = 5758 Nm

Axial Force Fax = 148975 N
Internal Pressure Pint = 4.137 MPa
Torsional Moment MT = 11518 Wm
Stresses
Fax Fd Mb
Longitudinal Stress Olong - +i
148975 4.137 X 168.3 57578

alcmg 3601x 103 4 X 7.112 1.392 X 10 S
ai 0 ng = 107.2 MPa
MT
Shear Stress T = 2Z
11S 18
T
2 X 1.392 x 10 s
T = 41.365 MPa
Hoop Stress
_ _ Pd 0
hoop 2
_ 4.137 X 168.3
ah Op ~ 2 X 7.
2
Ohoop = 48.94 MPa
_ (Mi, x rx )
Bending Component of u bending j
Longitudinal stress
r is the radius where the stress is being considered. This will be at a

*
maximum value at the outer surface where
rx = ra = d0 / 2 = 84.137mm
0bending ~
_ (5758 X 103 X 84.137)
1.171 xio7
bending = 41.37 MPa

INTERGRAPH
*
Torsional Stress The maximum torsional stress occurs at the outer radius where
again rx = 84.137mm
_ Mc x rx
Lmax 7 ,ax
_ 11518 x l O3 x 84.137
Tmax ~
2 x 1.171 x 107
Tmax = 41.365 MPa - at the outer surface

INTERGRAPH
'
3 D State of Stress in the Pipe Wall

During operation, pipes are subject to all these types of stresses. Examining a small cube of metal
from the most highly stressed point of the pipe wall, the stresses are distributed as so:
SR
/ SH
I
0P:
s
T 1 f
V .OIuBi
V
)
1
*- /1
- sL
SH S
R
There are an infinite number of orientations in which this cube could have been selected, each with
a different combination of normal and shear stresses on the faces. For example, there is one
orientation of the orthogonal stress axes for which one normal stress is maximised and another for
which one normal stress is minimised - in both cases; all shear stress components are zero. In
orientation in which the shear stress is zero, the resulting normal components of the stress are
termed the principal stresses. For 3-dimensional analyses, there are three of them and they are
.
designated Si ( the maximum), S2 and S3 (the minimum) Note that regardless of the orientation of
the stress axes, the sum of the orthogonal stress components is always equal, i e :..
SL + SH + SR = + S2 + S3
The converse of these orientations is that in which the shear stress component is maximised (there
is also an orientation in which the shear stress is minimised, but this is ignored since the magnitudes
of the minimum and maximum shear stresses are the same); this is appropriately called the
orientation of maximum shear stress. The maximum shear stress in a three dimensional state of
stress is equal to 'A the difference between the largest and smallest of the principal stresses (Si and
.
S3 )
The values of the principal and maximum shear stress can be determined through the use of Mohr's
circle. The Mohr's circle analysis can be simplified by neglecting the radial stress component,
therefore considering a less complex (i.e. 2D) state of stress. A Mohr's circle can be developed by
plotting the normal vs. shear stresses for the two known orientations (i.e. longitudinal stress vs.
.
shear and hoop stress vs shear), and constructing a circle through the two points. The infinite
combinations of normal and shear stresses around the circle represent the combinations present in
the infinite number of possible orientations of the local stress axes.
A differential element at the outer radius of the pipe ( where bending and torsional stresses are
maximised and the radial normal and force-induced shear stresses are usually zero) is subject to 2D
plane stress and thus the principal stress terms can be computed from the following Mohr's circle:
Tu
"
x
*
T- "
s2
\
-T-
'MAX

INTERGRAPH
"
The centre of the circle is at (SL + f[

SH ) / 2 and the radius is equal t + j . Therefore
T
2

the principal stresses S and S are equal to the centre of the circle, plus or minus the radius
2 2
respectively. The principal stresses are calculated as:
1/ 2
_ SL + $H ,
2~
Jl r
and
1/ 2
S2
SL + SH
2
-S
As noted above, the maximum shear stress present in any orientation is equal to Sl 2 or :
2
[ ( sL - sHy + 4T 2 ]1/ 2
,
T max '
2
Continuing our example:
Mohr s Circle of Stress

g|
ah
Centre of circle Center = n9
2
p
107.2 - 48.94
Center
2
Center = 78.07
Radius of Circle KmoHr =
Rmohr
Rmohr = 50.592 MPa
8
S2
78.07

INTERGRAPH
*
Maximum Principal Stress Si
along ~h fl/ioop \
z
, = 107.2 +J 48.94 + (107.2 +J 48.94)
/ \
s
J + 365
= 128.662 MPa
Or from the Mohr's circle above, Si = 78.07 + 50.59 = 128.66 MPa
Maximum Principal Stresses S2 and S3
&hoop
107.2 + 48.94 / 107.2 + 48.94 \ 2

1 J( 2 ) + 41365
52 = 21All MPa
Or from the Mohr's circle, S2 = 78.07 - 50.59 = 27.48 MPa
53 = S2

INTERGRAPH
*
Failure Theories
The calculated stresses are not much use on their own, until they are compared to material
allowables. Material allowable stresses are related to strengths as determined by material uniaxial
tests, therefore calculated stresses must also be related to the uniaxial tensile test. This relationship
can be developed by looking at available failure theories.
Failure of
cross section
Tensile Test Results
Unlxlal Tensile Tensile Test

Test Kachinc Specinen
There are three generally accepted failure theories which may be used to predict the onset of
yielding in a material:
Octahedral Shear or Von Mises theory

Maximum Shear or Tresca Theory
Maximum Stress or Rankine Theory
These theories relate failure in an arbitrary 3D stress state in a material to failure in the stress state
found in a uniaxial tensile test specimen, since it is that test that is most commonly used to
determine the allowable strength of commonly used materials. Failure of a uniaxial tensile test
specimen is deemed to occur when plastic deformation occurs, i.e. when the specimen yields; that
is, release of the load does riot result in the specimen returning to its original state.
The three failure theories state:
Von Mises: Failure occurs when the octahedral shear stress in a body is equal to the octahedral
shear stress at yield in a uniaxial tension test
The octahedral shear stress is calculated as :
TACT = - S 2) 2 + (S2 - S3 )2 + (S3 -
In a uniaxial tensile test specimen at the point of yield:
SI Syield ' $2 ~ S3 0

INTERGRAPH
Therefore the octahedral shear stress in a uniaxial tensile test specimen at failure is calculated as:
Toct = jJ(Syield of + (0 - 0) + (0 - Syield )

~ 2
2
Toct : V2
Therefore under the Von Mises theory:
Plastic deformation occurs in a 3-Dimensional

stress state whenever the octahedral shear stress
exceeds V2
Tresca: Failure occurs when the maximum shear stress in a body is equal to the maximum
shear stress at yield in a uniaxial tension test.
The maximum shear stress is calculated as:
_ - 53
t max- 2
Si = Syield i S2 = S = 0
Therefore
_ Syield ~ 0
-
1max
2
_ Syield
Imax 2
Therefore, under Tresca theory

stress state whenever the maximum shear stress
exceeds.'shield
2

INTERGRAPH
38
Rankine: Failure occurs when the maximum tensile stress in a body is equal to the
maximum tensile stress at yield in a uniaxial tension test
The maximum tensile stress is the largest, positive principal stress, Si ( by definition, Si is always the
largest of the principal stresses ) .
Si = Syjgiii i S2 = S3 = 0
Therefore, under Rankine theory:

stress state whenever the maximum shear stress
exceeds Syieid
Maximum Stress Intensity Criterion

Most of the piping codes use a slight modification of the maximum shear stress theory for flexibility
related failures. Repeating, the maximum shear stress theory predicts that failure occurs when the
Syi ld
maximum shear stress in a body equals ( the maximum shear stress existing at failure during
the uniaxial tensile test. Recapping, the maximum shear stress in a body is given by:
_ s1 - s3
Tmax ~
2
For a differential element at the outer surface of the pipe, the principal stresses were computed
earlier as:
J
!
Si I +_H ( ) + T2
S2 (or S3)
SL + (SL ~ SH\
)
2 J \ 2
As seen previously, the maximum shear stress theory states that during the uniaxial tensile test the
maximum shear stress at failure is equal to one-half of the yield stress, so the following requirement
is necessary:
t- max
v WL - SH )ry
2
+ 4r 2 _ Syield
ry

IlMItKOKAPH
Multiplying both sides by 2 creates the stress intensity, which is an artificial parameter defined
simply as twice the maximum shear stress. Therefore the Maximum Stress Intensity Criterion, as
adopted by most piping codes, dictates the following requirement:
V (SL - SH )2 + 4r 2 < Syield

Note that when calculating only the varying stresses for fatigue evaluation purposes, the pressure
components drop out of the equation. If an allowable stress based upon a suitable factor of safety is
used, the Maximum Stress Intensity criterion yields an expression very similar to that specified by
the B31.3 code:
Where:
Sb = longitudinal normal stress due to bending

St = shear stress due to torsion
SA = allowable stress for loading case
Continuing our example for the 6 diameter, standard wall pipe, in which longitudinal, shear and
hoop stresses were calculated:
along 107.2 MPa

T = 41.365 MPa
Oftoop = 48 94 MPa
Assuming that the yield stress of the pipe material is 206 MPa (30,000 psi) at operating temperature,
and a factor of safely of 2/3 is to be used, the following calculations must be made:
V (SL - sHy + 4T2 < lsyield
101.185 MPa < 137.33 MPa

The 101.185 MPa is the calculated stress intensity in the pipe wall, while the 137.33 MPa is the
allowable stress intensity for the material at the specified temperature. In this case, the pipe would
appear to be safely loaded under these conditions.

INTERGRAPH
*
40
Code Stress Equations

The piping code stress equations are a direct outgrowth of the theoretical and investigative work
.
discussed above, with specific limitations established by Markl in his 1955 paper The stress
..
equations were quite similar throughout the piping codes (i e between B31.1 and B31.3) until the
winter of 1974 when the power codes having observed that Markl was incorrect in neglecting
intensification of the torsional moment in a manner analogous to the bending component,
combined the bending and torsional stress terms, thus intensifying torsion.
It should be noted that the piping codes calculate exactly the stress intensity (twice the maximum
shear stress) only for the expansion stress, since this load case contains no hoop or radial
components and thus becomes an easy calculation. Including hoop and radial stresses (present in
sustained loadings only) in the stress intensity calculation makes the calculation much more difficult.
When considering the hoop and radial stresses, it is no longer clear which of the principal stresses is
largest and which is the smallest. Additionally the subtraction of Sj - S3 does not produce a simple
.
expression for the stress intensity As it turns out the inclusion of the pressure term can be
simplified by adding only the longitudinal component of the pressure stress directly to the stress
intensity produced moment loading only. This provides an equally easy to use equation and
.
sacrifices little as far as accuracy is concerned
The explicit stress requirements for the B31.1 piping code addressed by CAESAR II follows. Note that
most codes allow for the exact expression for pressure stress t0 be usin in place of in
the sustained stress calculations.
Note also that there are many additional piping codes addressed by CAESAR II .
1331.1 Power Piping
The B31.1 code requires that the engineer calculate sustained, expansion and occasional stresses,
exactly defined as below:
Sustained
0.75i MA P d0
Ssus = Sl = + r Sh
Where:
Sms, = sustained stress

r = intensification factor
MA = resultant moment due to sustained (primary) loads
Sh
=
JMX +2
My 2 + Mz 2
= basic allowable material stress at the hot (operating) temperature, as per Appendix A of
B31.1 Code. Sh is roughly defined as the minimum of:
1. 'A of the ultimate tensile strength of the material at operating temperature
2. '/ of the ultimate tensile strength of the material at room temperature
3. 5/8 of the yield strength of the material at operating temperature (90% of the
yield stress for austenitic stainless steels)
4. 5/8 of the yield strength of the material at room temperature (90% of the yield
stress for austenitic stainless steels)
.
5 100% of the average stress for a 0.01% creep rate per 1000 hours
(
INTERGRAPH
*
Expansion
SE = SA = /(1.25SC + 1.25Sh - S ) ,
Where:
SE = expansion stress range
Mc = resultant range of moments due to expansion (secondary) loads
,
Si
=
JMX +
2
My 2 + Mz 2
= Allowable expansion stress
Sc = basic allowable material stress at the cold (installation) temperature, as per Appendix A of
B31.1 Code
Occasional:
SQCC
_ 0.75i MA
y +
0.75i MB Pd 0
+ "4
_
Z
Where:
S0 Cc - Occasional Stresses
MB = resultant moment due to occasional loads
k
=
JMX +
2
M / + MZ 2
= occasional load factor
= 1.2 for loads occurring less than 1% of the time
= 1.15 for loads occurring less than 10% of the time.

INTERGRAPH
Pipe 1
Pipe 1
This exercise will provide further practise with the piping input, and introduce alternative editing
tools which may increase productivity in creating models. We will also investigate and review the
results to see what to look for and see how the piping system is behaving, and how to correct any
issues which may arise during the design.
The first stage of this exercise is to input the model. The model is below; you will also have the same
isometric printed on a separate hand-out in a larger format.
As before with the cantilever example, the model will be input using the node numbering system .
Each section between two nodes is called an element, i.e. node 10 to node 20 are linked together by
an element, referred to by 'element 10 to 20'. Prior to entering geometry, it can be very useful and
is a good idea to mark up the isometric drawing with the intended node number sequence.
tAW CL V\
K \J
Cx \
s
Of pa
Y USE B31.3
. .
12" & 10" PIPE STD WALL
- Coo . isciuLp
z X
A- 106 GR. B
TEMPERATURE = 330 0EG C
PRESSURE = 17.0 BAR
65mm CALCIUM SILICATE INS
..
FLUID S G = 0.72
. .
.
_ AiViOh 1,
CORROSION ALLOWANCE = 3mm
UrvvVi -f j U .
A AAM
I TVCMTCUOAU./ 3 )
eLM fiIcsi -
dJJ WA./
' 0'
rA. ik - .
'
V;
- CuA-At .
* %= E0
We will use a slightly different method of inputting the data, which will allow us to maximise the
graphics area during input. In the main Classic Piping Input , on each area, notice the symbol
in the top right corner:
Classic Pip ng Input
From: 10
Nome
O
To:
120

INTERGRAPH
*
Pipe 1
Double click this symbol to tear off the particular section of the input spread sheet. This will allow
the Classic window to be minimised for the most part thus maximising the graphics.
Tear off the Node Numbers, Dimension Deltas and Pipe Sizes areas. As the material temperatures
and pressures do not change throughout the model we can enter these on the first element and
then we will not need them again.
1
Input Model
Enter A106-B as the material, 330C as the temperature and 17 bars as the pressure
[
Temp 1: 330 0000
Temp 2: 1
Material (106)A106 B
Temp
Pressure 1 17 0000 El Allowable Stress
In this model we also require insulation; 65 mm thick Calcium Silicate.
InsulThk: 65.0000
Clad Thk:
Insulation Density: IlilMifiT

Amosite Asbestos
Cladding Density
or
Careytemp
Insul/ Cladding Fiberglass (Owen/ Corr
Unit Weight: Foam-Glass /Cellular G
The rest of the information we will need to enter for our model can be done via the three windows
we have "torn off . Minimise the Classic piping input (of course this can always be maximised at any
point if needed) .
ti
Auto H ide I
r
Finally we can enter the pipe size and schedule, along with the densities and corrosion allowance, as
per the isometric .
The fluid density can be entered as 0.72SG and CAESAR II will convert this specific gravity to the
correct units. As before the pipe size can be entered as 10 for 10 and S for STD schedule piping.

INTERGRAPH
*
Pipe 1
44
Edit Pipe Sizes X
Diameter MSB
Wt/Sch: 9.2710
Seam Wei ded
Wl Factor: |
-Mill Tol %: 12.5000
Corrosion: 13.0000
Pipe Density | 7833.43994
Fluid Density [ 719.67999
b
Propagate Properties
We will begin at the bottom right pipe where it is connected to a pump. This will be node 10.
Note that this is an anchor, a fixed point in our system. Element 10 to 20 is 400mm in length, in the -
-Z direction. Enter DZ as -400 mm
Edit Deltas
DX.
DY
DZ -400.000 mm
Offsets
Node 10 is also fixed so we need to specify an anchor. Use the toolbar on the left hand side of the
graphics window (default location) to specify a restraint.
'
B
0*
Oflb
Restraints
Add a restraint to each
of the selected elements
The Auxiliary Data - Restraints window will appear. Specify that the anchor is at node 10. The
auxiliary data window can now be closed.

INTERGRAPH
8
Pipe 1
Auxiliary Data
Node: 10 CNod
Type: ANC Ga
Stif: M
Our first element is complete, and should look like the one below:
Use the Continue button to create a new element:
1
nj Continue
Coni
Continue (next or new

Coi
: El element
ele )
This next element is a 300# flanged gate valve. We could enter this in a number of ways. The valve
will be rigid relative to the surrounding piping, so must be specified as a rigid element with a
.
weight This can be done either as 3 separate elements (flange - valve - flange), or as one overall
element with the total length and combined weight specified. This can be done manually or by using
the valve flange database to obtain the length/weight automatically from CAESAR M's catalogue,
.
which we will do Select the Valve flange database button and select a gate valve with flanged ends,
class 300.
1 Valve flange database

G
Access valve and flange
1 database
3
The Flange - Valve - Flange check box can be used to split the component into 3 elements
ifrequired.

INTERGRAPH
Pipe 1
46
Rigid Type End Type Class

[tai 150
1
GLOBE NOFLG RliliT
CHECK THREAD 600
CONTRL SOCKET 000
BALL 900
PLUG 1500
BTRFLY 2500
FLG.PR
FLANGE
Whole elemenl From end To end Both ends
1 Flange - Valve - Flange
Activate Flange Check

J
r 2K | Cancel
The element will appear in node 20 to 30.
The correct length will be inserted (and the element will continue in the same direction as the
.
previous element) Also note that the Rigid check box is checked and the rigid weight has been
entered with the relevant weight for a 300# gate valve and flanges. ( Hover briefly over the Classic
piping input where it is docked) .
I Bend Reducer
1 Rigid
Expansion Joint
SIFs ft, Tees Rigid Weight: 198 912

INTERGRAPH
"
Pipe 1
Continue to the next element S
Enter the DZ as -825mm. This element also leads into a bend, so press the Bend button on the right
hand toolbar. If using the classic piping input we could check the bend check box to achieve the
same result .
Bend
Place a bend at the 'to'
node of all selected
elements
The bend auxiliary data window will appear.
Auxiliary Data
Radius: Long
Type:
Angle 1 M Node 1 : 39
Angle 2 0 -000 Node 2: 38[

Angle 3 j Node 3:
S Miter Points
Fitting Thk.
K-fador
Seam Welded
The default bend type is a long radius (1.5D) bend This radius can be changed. Common bend radii
are available in the drop down, alternatively any radius required can simply be typed in here.
Radius: Irma
Type:
Long
3D
5D
Annlp 1 M Mnrln 1 1
3fl
In addition, further data can also be entered such as if the bend is flanged or mitred etc. Accept the
default long radius bend.
The graphics will not display the bend yet, as there is no following element.

-c
INTERGR
"
APH
Pipe 1
Continue to the next element .

This time we are now continuing in the -X direction. DX is -1050. The bend will now be visible in the
graphics.

This element is a 10 xl2 concentric reducer and is 203mm in length. Enter DX as -203mm and
specify that this is a reducer.
w
w
Reducer
Add a reducer to each of
the selected elements
The Reducer Auxiliary will appear and we can specify further data, including the second end size. A s
before, entering a nominal size in here will be converted to the actual OD. Enter 12 in the diameter
2 and S in the thickness 2 fields, which will be converted to the actual values.
Finally continue from the end of the reducer to the centre of the tee, 254mm as shown on the
isometric. DX is -254mm
The model at this point should now resemble the image below, note the node numbers in the image:
70
40

I
INTERGRAPH
Pipe 1
49
We can now take advantage of the fact that the model is symmetrical and use the functions in
CAESAR II to mirror the piping to create the opposite leg .
Use the Select group function to activate the graphical selection mode and draw a window around
the model.
, t > ifc @ 8 @ 8 III

1
Select Group
Selects Group of
Elements inside
Rubberband Box
.
All elements will turn yellow to indicate that they are currently selected Ensure all components are
selected .
The Duplicate function can be used to copy, and mirror if required, selected elements.
raf
f Duplicate
li
Duplicate elements in
block
Duplicate the selected elements and choose to mirror about the Y-Z plane.
[ Block Duplicate
Options
O Identical
j @ Mirror Y-Z I
ii ' Setup...
O Mirror X-Z
Mirror X-Y
We also need to increment the node numbers so that we do not have duplicate nodes.
Currently our model goes from node 10 through to node 70 .

If we increase the node numbers by 70, node 10 will become node 80, 20 becomes 90 and so on.
Therefore the second leg will be node 80 through to node 140. The only issue with this is that there
are no common nodes, so the piping will not actually be connected. This can easily be fixed by
chaging node 140 (the centre of the tee on the second leg) to become node 70 ( the node at the
centre of the tee on the first leg). This will connect up the piping at the common node, 70 - the
centre of the tee .

INTERGRAPH
*
Pipe 1
Node Increment 70|
Smallest Node Inside Block: 10

Largest Node Inside Block 70
Smallest Node Outside Block: 0
Largest Node Outside Block 0
[ OK Cancel
Click OK and the pipe will be duplicated, but as already stated there is no common node so CAESAR II
.
does not know where to place the pipe As such it locates it at the origin. The resulting model looks
like the following.
70
50
40
120
130
14
All we need to do is connect element 130 - 140 to element 60 - 70. This can be done by changing
.
140 to become node 70 Select element 140. There are various ways of doing this - either double
click in the graphics area, or user the navigation buttons to navigate to the correct element (as this is
the last element the end button will quickly take you to the correct element).
e>

>4
ena
Last Element
00
Go to the last element

INTERGRAPH
"
Pipe 1
The Edit Node numbers window should now read 13 to 140 and the element will be highlighted in
the model.
Edit Node Numbers
From: 130
To: 140
Simply change the To node from 140 to 70. The model will now be connected as should look like
the one below:
Edit Node Numbers
From: 130
To : 70|
'
120 70
130
SO
50
40
We can now complete the model by adding the vertical leg and connection to the vessel.
Skip to the last element This can be done by again using the Last Element navigation button or
using the Ctrl + End buttons on the keyboard.
Click Continue to move to the next element 4 . The node numbers will default to 70 to 80 We .
need to change this to 70 to 140.
Edit Node Numbers
From 70
To: 140

[
INTERGRAPH
*
Pipe 1
This element is the vertical leg, and is 7m in the Y direction. DY is therefore 7000. This also leads
0 .
into a bend so select the Bend icon as well. -
Click continue and place the final element 140 to 150 in the -Z direction, 2000mm. The final
element connects to the vessel, so we will place an anchor at this point. Click the retsraint button
and specify an anchor at node 150
Notice in the isometric that at the vessel connection, there are DY and DZ displacements. These are
due to the thermal expansion of the vessel.
O
B -
83
A*
Displacements
Insert displacements at
each of the selected
elements
Select the Displacements button and enter in the required values 3mm in DZ and 12 mm in DY.
Nodel : 150
Vector 1 Vector 2 Vector 3

DX
DY 12.0000
DZ 3.0000
RX
RY
RZ
Error Checking
The model is now complete, so run the error checker.
SB ttfrg
We will receive a fatal error and three warnings . We must correct the errors before we can analyse
the model. The warnings may be acceptable but we should check to confirm that the input is as
intended.
Message Element/ Message Text

Message Type Number Node Number
ERROR 57E 140- 150 At node 150 there is a DISPLACEMENT and a
RESTRAINT specified . This results in a numerically
overspecified boundary condition. The user should
either give the displacements of the point, or
restrain the point , but not both. If modelling
initial thermal movements at a restraint, define
some unique connecting node for the restraint, and
specify the displacement for the connecting node .

INTERGRAPH
Pipe 1
So our error is mentioning that we have both an anchor and displacements speciified at node 150.
This cannot be possible as the anchor fixes the point, but the displacements move the same point.
.
We cannot have both at the same time Remove the anchor and edit the displacements.
.
Double click the error message to go straight to the area of concern Now click the restraints button
.
to remove restraints Click OK in the message which appears. Now edit the displacements and fill in
0 in all other field (DX,RX,RY,RZ ). A displacement of zero will fix the node in that direction, so now
our node is fixed in all directions, except for DY and DZ where the relevant displacements are
applied.
Nodel 150
1
Vector 1 Vector 2 Vector 3 Ve
DX 0 0000
DY 12 0000
DZ 3 0000
RX 0 0000
RY 0 0000
RZ 0 0000
< TTT
Re run the error checker and investigate the warnings. The second two warnings are regarding the
reducer alpha angle which is not specified. CAESAR li is therefore using a default computed value .
This is acceptable here for us.
The first warning is stating that there is a geomtric intersectaion at node 70 (the tee) but we have
not specified a type of tee, and therefore a SIF. This can sometimes be correct but is most often the
.
result of an oversight, as in this case Return to the input and locate node 70. The Find tool can be
used to do this:
10 T j- oj:
Find Node
Find Node operator
The Zoom to Node if found check box will also zoom into that node/element if it is found, useful on
larger models.
Find Element
Node Numbers
[70
|| BZoomtoNodejlFouri ||
OK ] Cancel

INTERGRAPH
*
Pipe 1
On node 70 use the SIFs/Tees button to specify a SIF at this point. This only needs to be done on one
of the elements connecting to node 70, it is not necessary to do this on all three.
3
m
E
0
-
K
SIFs / Tees
Insert an SIF/Tee
definition at each of the
P-
selected elements
Select an unreinforced tee.
Auxiliary Data
Node 70
I Type 2 - Unreinforced C
f SIF(i) 1 - Reinforced r
-
SIF(o) 3 Welding r
.
Re-run the error checker All should now be OK, only the reducer alpha warnings will remain, plus
the C of G report.
Review Load Cases

Access the load case editor
S 10 8=
.0 ,
Edit Static Load Cases is
Start Static Analysis
.
Notei -rr
Recall from earlier the design code (we are using B31.3) addresses the stresses produced by the
various loads. In our model we have the following loads applied:
Weight
Pressure
Temperature
Displacement
B31.3 requires that two checks are performed - Sustained and Expansion
Sustained - Weight and Pressure

Expansion - Temperature and Displacement

INTERGRAPH
*
Pipe 1
These load cases are defined by CAESAR II as the default (recommended) load cases, shown in rows
L2 and L3.
IQS A &
Lood Cose Editor Load Cass Options Wind Loads Wavs Loads
Loads Delined in Input Load Cases | Stress Type | Recommend

-
W Weight L1 W+D1+T1+P1 OPE
-
D1 Displcmnt Case #1
L3
W+P1
L1-L2
SUS
EXP Load Cycles
T1 - Thermal Cese #1
-
PI Pressure Case #1
WW - Water Filled Weight Import Load Cases
WNC - Weight no contents
Row LI is an operating case (OPE) and is the Hot case consisting of the 'real world' loads. This case
is not required by B31.3 (although some codes do require this case also). However as this case is a
real world scenario it is used to estalish restraint loads and loads on equipment conections. In
.
addition, it is used to derive the Expansion case The expansion case is the algebraic difference
between LI and L2 (LI - L2 ).
Accept these load cases and run the analysis by clicking the Running Man icon.
Review Results
After the analysis has run, the output processor will appear. The first thing to notice is that the EXP
case is coloured red. This indicates that this case has failed to code stress check. That is, the
computed stresses in the system at some point are greater than the allowables published in the
code.
We need to fix this .

Select the Expansion case and view the results for the Stresses report.

INTERGRAPH
0
ES4R
" stati
IEJBB
*
pii Static Output Processor - [D:\TRAINING\CAESAR II\PIPE1]
\ File .
View Filters Reports Options Plofr , " ' PlotView Show Window
Jiiaaaa aa
L 71 \ / +
flew Reports
Load Cases Analyzed Standard Reports

1(OPE) W+D1+T1+P1 Displacements
Restraints
2 (SUS) W +Pl Restraints Extended
3 (EXP) L3 =L1- L2 Local Restraints
Restraint Summary
Nozzle Check
Range Peq
Range NC-3658 3
Global Element Forces
Stresses Extended
Stress Summary
The report shows that the code stress check failed and highlights in red where the check failed.
Double dikcing on any column will order the report by that coluumn. Double click on the Code
Stress column header to order by highest stress.
(3)Stress
CAESAR II 2011 SP1 Ver.5.30.01, (Build 110229) Dace: JUN 3, 2011 Time: 13:53
Job: D:\TRAINING\CAESAR II\PIPE1
STRESSES REPORT: Stresses on Elements
CASE 3 (EXP) L3 L1 L2
Bending
Stress
- -
Torsion
Stress SIF In SIF Out
Allowable
Code Stress Stress Ratio Piping Code
NODE Plane Plane N./sq.mm. %
N./sq.mm. N./sq.mm. N./sq.mm.
Piping Code: B31.3 = B31.3 2008, December 31, 2008
CODE STRESS CHECK FAILED LOADCASE 3 (EX?) L3 L1 L2 = -

Highest Stresses: (N./sq.mm. )
CodeStress Ratio (%): 161.6 @Node 70
Code Stress : 439.7 Allowable: 272.0
Axial Stress: 12.5 @Node 138
Bending Stress: 438.4 Node 70
Torsion Stress: 24.7 @Node 40
Hoop Stress: 0.0 fiNode 20
3D Max Intensity: 634.0 0Node 70
70
70
438.37
438.37
-16.85
16.85 4.625
4.625
5.833
5.833
439.66
439.66
272.04
272.04
161.61
161.61
B31.3
B31.3
70 393.11 0.00 4.625 5.833 393.11 281. B 3 139 - 49 B31.3
10 298.68 21.69 1.000 1.000 301.81 272.20 110.88 B31.3
80
150
298.68
257.31
--
21.69
0.00
1.000
1.000
1.000
1.000
301.81
2S7.31
272.20
275.55
110 88
93.38
331.3
B31.3
20 223.84 -
21.69 1.000 1.000 228.01
228.01
282.70
282.70
80.63
80.63
B31.3
B31.3
90 223.84 21.69 1.000 1.000
The overstress points are at nodes 70, 10 and 80.

f
INTERGRAPH0
Pipe 1
.
First we will check node 70 This is the tee. Look at the SIFs here. The in-plane SIF is 4.625 and the
.
Out-Plane is 5.833 The stresses at this point are therefore being multipled by 4 and 5 times. If we
can reduce these SIFs then the stress will reduce and can easily be reduced below the code
allowable.
Bending Torsion Allowable

SIF In Ratio
JODE Stress
N./sq .mm.
Stress
N./sq.mm. Plane
SIF Out
Plane !!ode Stress
/sq.mm.
Stress
N./sq.mm.
% Piping Code
70 438.37 16.85 | 4.625 5.833 439.66 272.04 161.61 B31.3

70 393.11 0.00 4.625 5.833 393.11 261.83 139.49 B31.3
10 298.68 21.69 uuu 1 301.81 272.20 110.88 B31.3
BO 298.68 -21.69 1.000 1.000 301.81 272.20 110.80 B31.3
150 257.31 -0.00 1.000 1.000 257.31 275.55 93.38 B31.3
20 223.84 -21.69 1.000 1.000 228.01 282.78 80.63 B31.3
.
Return to the input and return back to node 70 Pick the Intersection SIF scratchpad and choose
node 70.
Intersection SIF scratchpad

0 Use intersection SIF
Q scratchpad
V
Change the unreinforced tee to a reinforced tee. Specify a pad thickness of 10mm
Node:
Type: 1 - Reinforced
( PadThk.
110.000 | Heat
Click the Recalculate button and notice the SIFs reduce dramatically. Now the stresses will be
multplied by 2.887 and 2.415 rather than 4 and 5 .
Header SIF(i): 2.415

Header SIF(o): 2 887
Branch SIF(i): 2 415

Branch SIF(o): 2 887
(
INTERGRAPH
Pipe 1
58
Re-run the analysis using the batch run feature. The Expansion case is still shown in red, indicating
.
the system is still overstressed But check the Stress report for the Expansion case and notice that
only nodes 10 and 80 are overstressed.
Bending Torsion Code Stress

All'
SIF In SIF Out Str >
NODE Stress Stress
Plane Plane N./sq.mm. ./
N./sq.mm . N./sq.mm. N
10 298.68 21.69 1.000 1.000 301.81 |

80 298.68 - 21.69 1.000 1.000 301.81
150 257.31 - 0.00 1.000 1.000 257.31
70 228.64 -16.85 2.415 2.887 231.11
70 228.64 16.85 2.415 2.887 231.11
So what is happening at nodes 10 and 80 ?
Nodes 10 and 80 are the initial anchor locations, so we need to find out what is causing the
overstress. This is in the expansion case, so if we recall the code equation for the expansion case:
[(iiMi) 2 + (i0M0) 2 + 4Mj 2 ] 1

'
2

Se ~ Z
From this equation it can be seen that the dominant factor in the code equation is the bending
.
moment - it is the only factor in the expansion case So which bending moment is this, M|, M0 or Mt?
,
M is torsion, M, and M| and Mc are inplane and outplane - so vary dependant on the location. What
we can see from the results though, is which bending moment is the highest in terms of our axes .
View the Expansion case, Restraint Summary report.

1(OPE) W+D1+T1+P1 Displacements
Restraints
2 (SUS) W+Pl Restraints Extended
3 (EXP) L3=L1-L2 Local Restraints
Restraint Summary
Nozzle Check
We can see from this report that at nodes 10 and 80, the highest bending moment is the MY
moment, at 116 kN.m. The MX is also rather high at 88 kN m . .

INTERGRAPH
*
Pipe 1
(3)Restramt Summary
CAESAR II 2011 SP1 Ver.5.30.01, (Build 110228) Date: JUN 3, 2011 Time: 14:12
Job: D:\TRAINING\CAESAR II\PIPE1
Licensed To: Seat ID #S1
RESTRAINT SUMMARY REPORT: Loads On Restraints
CASE 3 (EXP) L3=L1 L2
- A
FX FY F2 MX MY MZ
Load Case
N. N. N. N.m. N.m. N . m.
LOAD CASE DEFINITION KEY
10 Rigid ANC
3(EXP) 70590 -58673 7023 -88663 -116451 21262
80 Rigid ANC
3(EXP)
-
70590 -58673 7023 -88663 116451 -21262
So we know what is causing the overstress, but how do we correct this and reduce the bending
moment (and therefore the stress)?
Let us look at the 3 D plot to view what is causing the bending moment.
Close the report and view the 3 D plot

cii Static Output Processor - [D:\Tf
j File View Filters
I B B H B 3P B ILie . atj
Options Plot
j
* -
'
DF I3
In the 3D plot window which appears, ensure that the Load case we are viewing is the expansion
.
case and select to Show the deflected shape You may need to Adjust the deflection scale to get a
more exaggerated deflected shape .
pii Static Output Processor - [D:\TRAININ
j File View is Options PlotOptions
-+ yt k @ QB
! Load Case: 3 (EXP) L3=L1- L2
jjSjrgg JlhCfr jJjiX $ & <i

- fi
Show Deflected Shape

la just Deflection Scale
View the pipe from the bottom, using the standard views available
[iflfl 1 1 8 8

INTERGRAPH
"
CAOWorx & Analysis Solutions
Pipe 1
60
1s
1
We are looking upwards at the pipe from below. The Y axis is pointing upwards ( away from us ). The
pipe is undergoing thermal expansion and causing the pipe to bend at the anchor points.
Looking at the model from the side view will also explain the MX moment. As can be seen, the riser
is expanding causing the MX bending moment.
If we could add some flexibility in to the area where the pipe is expanding we can absorb some of
this expansion, and so reduce the bending moment. We have the top leg which is flexible, but the
bottom leg is not flexible enough.

INTERGRAPH

Pipe 1
Flexible
C Kq
Not flexible enough
If we can transfer some of the flexibility in A to B then we may solve the problem.
To do this, increase the length of B by lm and so consequently reduce the length of A by lm. This
should give us more flexibility at the bottom, hopefully without removing too much flexibility at the
top.
Return to the input and select element 30 to 40. The DZ value here is 825mm. Edit this to 1825mm.
Copyright 2011 Intergraph CADWorx &. Analysis Solutions

INTERGRAPH
*
Pipe 1
Edit Node Numbers f x
From: 130 Name

To:
(jO
Edit Deltas
DX
DY
DZ j-1825 000 mm
Offsets
Repeat for element 100 to 110.
We will have to also consequently reduce the length of 140 to 150 by the same amount ( lm).
Change this from 2000mm to 1000mm.
Edit Node Numbers t x
From: |l40
L Name
To: fiiT
Edit Deltas
DX:
DY:
DZ: 1-1000.000 mm
Offsets
The model should now look like the one below.

ImtKtjKAPH CAESAR II Statics Training
Pipe 1
CADWorx' & Analysis Solutions
.
Re run the analysis and check the results The expansion case is now no longer coloured red and the
.
highest code stress is 91% of the allowable at node 10 We have successfully reduced the stresses
and the model now passes the code stress checks.
Verify the sustained stress report that this is still acceptable - it should be around 37% of the
allowable .
Our model is now compliant with B31.3.

INTERGRAPH
0
Supt 01
64
Supt 01
This exercise is designed to demonstrate adding supports in CAESAR II and demonstrate the
Operating case and Restraint load reports and give an indication of what the results mean on the
restraint load report, along with a short example on how to combat issues with supports, such as
lift off .
PIPE -
UAT 'L
12 DIA SID SCH
A- 106 OR B
riUlD - WA1ER
PRESSURE - 10.5 BAR
TCM? - 175 DECREES C
ELBOWS
INSULATION
- - 50 RADIUSCS
LONG
mrn
VALVES - 50# GATE VALVES (3675 h
40
NOZZLES (ANCHOR POINTS) Q 10 & S
20
ili
30
HO
90
70
GO
Z X
The model shown above will also be in your hand-out. Model the piping system as per this
isometric. Anchor at nodes 10 and 90.

INTERGRAPH
*
SuptOl
Locating Supports
The system is anchored at the termination points (nodes 10 and 90), but we also need to support the
weight of the piping system as well.
If both supports are pinned (free to rotate), standard beam theory states that the max moment is at
the centre of the span, /.
A A
This moment is:
( Mmax g
If both ends are fixed then the max moment is at the end of the span
\
\
\
/
/ \
\
/ \
/ \
This has a value of
wl 2
Mm 12
Where
M max = max moment in the beam

w = uniform weight of pipe (fluid , insulation etc)
( l = length of beam
As piping systems are neither one nor the other and tend to be somewhere in the middle, a
compromise therefore is reached with an approximation thus;
wl 2
Mmax ~ JQ
Taking into account the maximum moment could be somewhere between the ends and the centre -
i.e. anywhere along the span.
(
INTERGRAPH
0
Supt 01
66
This deals with continuous runs of pipe, however there are of course concentrated loads sometimes
in the piping system, such as valves, flanges etc. The effects of these items on the pipe stresses can
.
be estimated as well For pinned connections, the maximum moment is located at the point of
loading ( P ).
P
zs CXI *
This maximum moment has a value of
Pab
Mmax ~ ;
Where a = longer portion of span

b = shorter portion of span
For fixed connections:

P
\
/
Fie maximum moment here is located at the end nearer the load, and has a value of
Pa2 b
=
max
J2
In either case (or in some case in between) the additional stress ( M/Z) due to the concentrated loads
should be added to the stress from the uniform load in order to determine the total stress .
Examining the formulas above, it can be seen that as the shorter span ( b) approaches zero in length,
the moment, and therefore the stresses approach zero as well.
So, if supports are located as close as possible to concentrated loads, the effects of these loads are
reduced as much as possible.

V'
IIMILKIJKAPH

Supt 01
The information on the preceding pages provides a simple rule of thumb to design for weight
loading.
First support all concentrated loads in the system as closely as possible, reducing the stresses due to
those loads to as close to zero as possible.
Next, we can use
,
M1max =
wl 2 ...
Along with a =
M
If we knew the allowable stress, we could then use this information to determine a maximum
allowable length of pipe - i.e. a distance between supports.
Rearranging the equations above, we can obtain
10 Zffali
lan = allowable pipe spanfor weight loading

Z = section modulus of pipe
aaii = approximate allowable stress of material for weight stresses

As this calculation will need to be done often, in order to save time calculating laa the Manufacturer
Standardisation Society of the Valve and Fitting Industry has calculated allowable piping spans for
.
various configurations These standard spans have been published and are shown on the next page.
These spans assume:
The pipe is standard wall with insulation

Maximum moment is Mmax = wl2/10
No concentrated loads are present
There are no changes in direction
Maximum allowable stress is taken to be approx. 10 MPa
Max deflection is approx. 2.5mm
SIFs are not taken into account
It is rare that piping systems are only horizontal runs with no changes in direction etc.; therefore a
caveat is taken in that changes in direction reduce the allowable span to % of the standard span .
In addition, the standard span does not apply to risers, since no moment (thus no stress) develops,
.
regardless of length However it is preferable to locate supports above the centre of gravity of the
riser to prevent toppling.
These rules here are simply rules of thumb and can provide a good start point for support locations.
Of course, supports should be located with practical considerations taken into account (locations of
building steel/pipe racks etc.).

INTERGRAPH
*
Supt 01
68
in
=
3
g*i g
8
FOLLOW PIPE MANUFACTURER'S RECOMMENDATIONS FOR SPACING AND
SERVICE CONDITION .
i
Z
k
e
FOLLOW PIPE MANUFACTURER'S RECOMMENDATIONS FOR MATERIAL AND
. s
E
SERVICE TEMPERATURE
I
SPACINO o
CLAS 1 ft (2.4m) MAX SPACING,FOLLOW MANUFACTURER'S RECOMMENDATIONS.
SEE SECTION II . jjl
SAUPNODRT as
ASBETO CEMNT FOLLOW PIPE MANUFACTURER'S RECOMMENDATIONS .

1
.
p
CAST IRON SOIL

10 ft (10m) MAX SPACING MJN OF ONE (1) HANGER PER PIPE SECTION CLOSE
TO JOINT ON THE BARREL ALSO AT CHANGE OF DIRECTION AND BRANCH
CONNECTIONS . 1
HPAMIPEER
.
1J ft IJ Jml MAX 5FACINC MIN OF ONE fl) HANGER PER FIFE SECTION CLOSE
TO JOINT ON THE BARREL AISO AT CHANCE OF DIRECTION AND BRANCH
CONNECTIONS .
1
ail

FIRE PRO

TECION FOLLOW REQUIREMENTS OF THE NATIONAL FIRE PROTECTION ASSOdA

.
T10N SEE SECTION 14 . - gl
i.
ins
HORIZNTAL *
TUBE VAPOR SERVIC
COPER WATER SRVICE =
a 2 P 2 2I2
C
E 2
0 'C
P
2222
P 0 0>
p
P P
2
=
P
5P
n r v
Q p
*
p p
a
2P
s22s
p Q P P P 9
P
2 PI
M
m
MAXIU . PIPE VAPOR SERVIC

E
c
552252
0 m . 0>
p P
n m
n P p p P
2 70

3
* sSS
n P
252
S ?? 2 K R
n 522
w
J
pi
ii
ill
i
TE L
0
*
k
3
-
TABLE
1
|
WTS P
2P P n N
22 P P p
2 2I
STD WATER SERVICE
E 22222 2
-
r* r* r* K 0> O r
* m
* P 2 2 VJ sS 22
1
83
PI E SIZE 5555 c U SS
n '
NOMIAL
OR - E n
* VI <c a o <s P <0 a
8 28 ii
TUBE 1 i
i .

INTERGRAPH
*
Supt 01
69
Adding Supports to Model

Let us now return to our model SUPT01.
20
-
to
-
k >09
5 30
BO
90
70
00
As there is an anchor at node 10, the valve here is supported .

The valve at 60-70 requires supporting. We will create a new node on element 50 to 60, called 57,
and locate a +Y support here.
Use the Break command to split the element into two. First select element 50 to 60 and choose the
break command.
a Classic Piping Input

W From : 50
m l0 : 60
Name
3C
A>

o Break
a Break current element
s DZ: |-6805 000 mm
.
We will locate this support close to the valve ( node 60) Specify to break the pipe and insert the new
node, number 57, 150mm from node 60:

INTERGRAPH
Supt 01
>
IftzrMr .
Insert Single Node
InsertMultiple Nodes
Single Node Informal,inn

New Node Number 57
Distance from Node 50 150 000 mm

in (mm )
| o (fom Node 60
Multiple Node Information

Total Number of Break Elements
Node Step
Length of each element
Allow Duplicate Node Numbers
Get Support From Node
QK Cancel
The element will be broken and a new node inserted close to the valve. Locate a +Y support at this
node 57.
r Node 57 CNode
E Restraints I [ Displacements Y
Type Gap
HrTHangers U Flange Checks
Nozzle Flex. Nozzle Lmt Check Stif Mu
The +Y support will support the pipe from below, and will allow movement in the +Y direction.
All the concentrated loads are now supported.
We can return and run through the piping system, placing supports as per the standard span.
Check the table on page 48 to determine the maximum span for 12 pipe carrying water

INTERGRAPH
*
Supt 01
The table on page 48 indicates that the maximum span for 12 pipe in water service is 7m As .
discussed previously, for horizontal changes in direction, the support span is amended to 3A of the
standard span. 0.75 x 7 = 5.25m
The valve is supported at node 10. After node 10 the piping continues horizontally with a bend. The
maximum span therefore is 5.25m. This places our support round the bend .
5!<s 30
I *
*
The piping after the bend is 13715mm before the riser. This can almost be split in two exactly with
our 7m span spacing. Remember that the standard span does not apply to risers, and as mentioned
before we will support the riser from the top, rather than trying to balance it from the bottom. As
such we can locate a support near the middle of the 13715mm run, and one close to the bend (node
30).
.
Break element 30 to 40 and locate a new node number 33 Locate this 600mm from node 30.
It is possible to add a support in at the new node location. We wish to add a +Y support at node 33,
exactly the same support configuration as at node 57. So typing in 57 in the Get Support from
Node field will place the same support as at 57 at our new node 33.
a Insert Single Node
Insert Multiple Nodes
Single Node Information

New Node Number 33
Distance ? from Node 30

600.000 mm
ln (mm )
from Node AO

Node Step
Get Support From Node S7|
[ QK ancel
fr -

INTERGRAPH
*
SuptOl
Repeat and break element 33-40. Break this 7000mm from node 33. Call the new node 37. Place
the same +Y support from 33 (or 57) at this point too.
> UiK . I TJ I
I /El[l]|
AT (
Insert Single Node

New Node Number 37
Distance (rom Node 33 7000 000 mm

in (mm ) Q from Node 40
J
Node Step
Get Support From Node 33
Cancel
Continue on after the riser. There is already a restraint next to the valve, so we have fulfilled the
minimum span up to the valve. After the valve we have horizontal pipe with a bend again.
Therefore our maximum span is 5.25m. The length of pipe is 4115 mm and then 3640mm after the
bend. There is an anchor at the end, so we just need one more support between the valve and the
anchor at the end of the pipe.
80
-.
S'
90
70
60
Locate this support on element 70 to 80; close to the bend at node 80. Locate this 600mm from the
bend.
Break element 70 to 80 and create a new node 77, 600mm from node 80 and with a + Y support the
same as before.

INTERGRAPH
'
Supt 01
o Insert Single Node

New Node Number 77
Distance from Node 70 600.000 mm

in (mm.) @ jff0m Node 80)
J
Node Step
Length ol each element
Allow Duplicate Node Numbeis
OK Cancel
Finally the piping riser needs to be supported. The length of horizontal run at the top and bottom of
.
the riser is less than our span of 7000mm There is no bending in the riser so in theory we can place
a single restraint near the top of the riser.
Break element 40-50 and locate a +Y restraint 600mm from the tangent intersection point of the
bend. Note that, although this support should satisfy our bending requirements on the horizontal
sections, it may have a very large load since it will also support the whole of the riser.

New Node Number 43
Distance from Node 40

ln (mm')
from Node 50
OK | Cancel

INTERGRAPH
"
SuptOl
The support located in the riser may be difficult to see, as it is probably hidden by the piping. To
view the support either the size of the restraint symbol can be increased, or the pipe can be set to
translucent mode.
jrjdgp
EH ~ *
Largest
Larger
16
ff
'.'."IT? Medium
X E, Smaller
0 L Smallest
a v Only w/ CNodes
3 None w/CNodes
*
|j t A It B9S J IllJlfin snfi)
Translucent Objects
Makes objects
'see- through'
Reducer
IHPICA o
If
The system is now supported as per the maximum span requirements. We can be sure that the
sustained stress case therefore is acceptable, and should be in the order of approximately lOMPa.
Error Check the model.

i !
<
da p* -
You should receive only the Centre of Gravity report, and no errors or warnings.

INTERGRAPH
"
Supt 01
Analyse
Access the Static load cases create only a single load case with weight only. We wish to check the
support locations we have just placed are below the acceptable limits
IS <j
!i Q -
Start Static Ana ysis
ulngs: 0 Note
|
Load Cose Editor Epad Case , Options j Wind Loads Wave Loads
Loads Defined in Input Load Cases Stress Type |

W - Weight Ii |W SUS
T1 - Thermal Case #l
Run the analysis.
View the Sustained Stresses report.
ii Static Output Processor [D:\TRAINING\CAESAR II\SUPT01]

-
File View Filters Reports Options PlotOptions PlotView Show Window
I B B IDIA 3 0 a a @s
.
y + - View Reports

1(SUS) W Displacements
Restraints
Restraints Extended
Local Restraints
Restraint Summaiy
Restraint Summaiy Extended
Nozzle Check
Range Peq
Range NC-3658.3
Stresses Extended
Stress Summaiy
Code Compliance
Code Compliance Extended

INTERGRAPH
Supt 01
CAESAR II 2011 SP1 ver . 5.30 01, .

( Build 110226 ) Date : JUN 13, 2011 Time : 15 : 45
Job : D: \ TRAINING \ CAESAR IIlSOPTOl
Licensed To : Seat ID # 51
STRESSES REPORT : Stresses on Elements
CASE 1 fSUS ) W

SIF In SIF Out Code Stress Ratio
NODE Stress Stress Stress Piping Code
N . / sq.mm. t
.
N . / sq mm . N . / sq .mm .
Plane Plane N . / sq .mm .
Bending Stress : 10.7 8 Node 37

Torsion Stress : 0.7 SNode 29
Hoop Stress : 0.0 8 Node 20
3 D Max Intensity : 10.7 @ Node 37
37 10.67 0.04 1.000 1.000 Q 10.67 I 137.89 7.74 B 31.3

37 10.67 -0.04 1.000 1.000 10.67 137.89 7.74 B31.3
57 9.89 0.06 1.000 1.000 9.89 137 . B 9 7.17 B 31.3
57 9.89 -0.06 1.000 1.000 9.89 137.89 7.17 B31.3
60 8.31 0.06 1.000 1.000 8.31 137.89 6.03 B 31.3
The highest stress level is 10.7 MPa , which is almost exactly at the allowable from the standard span
limit (this limit is based on an allowable of 1500 psi ~ 10.3MPa ) . The system is supported from a
purely weight induced stress perspective .
We can also now view the restraint loads to see how the weight loads are distributed . View the
Restraint Summary report .
RESTRAINT SUMMARY REPORT : Loads On Restraints

CASE 1 ( SUS ) W
FZ MX MY MZ
NODE Load Case
N. N.m. N.ra. N.m.
CASE 1 ( SUS ) W
10 Rigid ANC
1{SUS ) 2 -6442 -28 -927 66 - 2583
33 Rigid + Y
1 ( SUS ) 0 -7337 0 0 0 0
37 Rigid + Y
l ( SUS ) 0 -12054 0 0 0 0
43 Rigid + Y
l ( SUS ) 0 -30705 0 0 0 0
57 Rigid + Y
l ( SUS ) 0 -13746 0 0 0 0
77 Rigid + Y
l ( SOS ) 0 - 4792 0 0 0 0
90 Rigid ANC
1 ( SUS ) -2 -3548 28 -257 82 27 S3
(
IIMILKUKAPH
CADWorxs & Analysis Solutions
Supt 01
Again this look OK, all restraints are taking a downwards acting load (-FY), although the restraint at
node 43 is rather large compared to the others; 30,000N vs. less than half that for the remaining
supports .
These loads however are due to weight only. Let us run now the cases required by the piping code
B31.3. Return to the Static Load cases and select the recommended cases.
Loed Case Editor Load Cose Options Windloads Wave Loads I
Loads Defined in Input Load Cases | Stress Typo Recommend

W Weight 11 W+T1+P1 OPE
-
T1 Thermal Case #l L2 WtPl sus
LoadCydes
-
PI Pressure Case 01 13 LI 12 EXP
-
WW Water FIIed Weight
-
WNC Weight no contents Import Loed Case
Run the analysis and view the sustained stresses. These will have increased slightly due to the fact
that we are now including the pressure term; however the stresses are still well within the
allowables determined by the code.
Similarly the Expansion Case stresses are also very low and well within the allowable - the system is
flexible unlike the PIPE1example.
Now we can check the restraint loads in the real world operating case. Remember the Operating
case is not required by the code, but it does represent the actual loads in a real world scenario, for
the purpose of designing restraints.
View the Operating case Restraint Summary .

INTERGRAPH
*
Supt 01
78

CASE 1 (OPE) W+T1+P1
FX FY MX MY MZ
NODE Load Case .
.
N. N. N.m. N.m. N.m .
10 Rigid ANC
1(OPE) 60 - -5769 1B90 -1093 -5646 -1195
33 Rigid +Y
1(OPE) 0 -B 646 0 0 0 0
37 Rigid +Y
1(OPE) 0 -9071 0 0 0 0
43 Rigid +Y
1(OPE) 0 -25305 0 0 0 0
57 Rigid +Y
1(OPE) 0 -29236 0 0 0 0
77 Rigid +Y
1(OPE) 0 0 0 0 0 0
90 Rigid ANC
1(OPE) 60 -596 -
1890 -1569 - 6060 -8071
The loads are different to before as we have included the effects of thermal expansion.
.
The load on node 77 is 0 (in the FY) This shows that this restraint is not taking any load. What is
happening here?
View the displacements report to see what is happening at this point .

\
DX DY DZ RX RY RZ
NODE mm. mm. mm. deg. deg. deg.
so -8.503 26.211 19.297 0.2236 -0.0042 -0.0632

57 -7.822 -0.000 7.796 0.1184 -0.0094 -0.0633
60 -7.797 0.285 7.518 0.1044 -0.0096 -0.0634
0.0634
70 -7.712 1.200 6.575 0.1024 -0.0096 -0.0635
77 -6.955 2.307 0.052 -
0.0221 -0.0154 -
At node 77 the pipe is moving upwards 2.3 mm. Also notice that at node 50 (the bottom of the riser)
the pipe is moving down 26mm.

INTERGRAPH
*
SuptOl I 79 |
Viewing the 3 D Plot can confirm this:
CII Static Output Processor - [D:\TRAIN

j File View Filters Re ortc nptinnc PlotOptio
|! Q ID 13 10 1Ftx a
+ 1 P pM
>
Load Cases Analyzed

1(OPE) W+T1+P1
View the deflected shape (you may wish to increase the deflection scale to exaggerate the deflected
shape)
m Ji -o- $ si JiX -
gg show Deflected Shape
Adjust Deflation Scale
3c
t
The 3D plot shows that the thermal expansion is causing the riser to expand downwards at the
bottom (node 50). This in turn is causing the pipe to pivot at node 57 - giving the large operating
load at node 57. The pipe pivoting at 57 causes lift off at node 77 - so we see a 0 load.
The restraint at the top of the riser (at 43) is the datum point of expansion and so all the thermal
expansion is from this point. That is why there is no expansion at the top and a lot of expansion at
the bottom. We need to rectify this situation.

INTERGRAPH
*
Supt 01
80
Fix Model
As we know, the riser is expanding due to thermal expansion. The datum point for this expansion is
the support located at node 43, at the top of the riser, so all the expansion is going downwards -
causing the lift off issue. To rectify this we can attempt to move the datum point of the expansion,
so that the expansion is more evenly distributed.
Insert an additional restraint on the riser. Call this node number 45 and locate this restraint 6000mm
below node 43. Insert another +Y support at this location. This should have two effects:
1. Give a better distribution of

the weight loads of the riser
2. Cause less thermal expansion

downwards at node 50.
Re-run the analysis, the batch run command can be used as we have only made a small change by
adding a support.
JIB a h
<b
i *
Batch Run
Error check and analyze
job
.
Review the stresses is the SUS and EXP cases These stresses should still be acceptable .

INTERGRAPH
Supt 01
Review the restraint report for the sustained and operating cases to see how the new restraint has
affected the results.
CASE 2 (SUS) W+Pl
NODE Load Case

FX FY FZ MX MY MZ
N. N. N. N.m. N.m. N.m.
10 Rigid ANC
2(SUS) 2 -6442 -30 -927 73 -2583
33 Rigid +Y
2(SUS) 0 -7336 0 0 0 0
/ 37 Rigid +Y
2(SUS) 0 -12055 0 0 0 0
43 Rigid +Y
2(SUS) 0 -8816 0 0 0 0
45 Rigid +Y
2(SUS) 0 -21905 0 0 0 0
57 Rigid +Y
2(SUS) 0 -13706 0 0 0 0
77 Rigid +Y
2(SUS) 0 -4016 0 0 0 0
90 Rigid ANC
2(SUS) -2 -3546 30 -252 90 2748
The sustained case shows that we have a better distribution of the weight of the pipe on the riser, as
the new restraint is taking some load . The load on node 43 at the top of the riser is now distributed
between 43 and 45 ( 43 has dropped from 30 kN to 9 kN ).

INTERG
*
RAPH
Supt 01

CASE I (OPE) W+T1+P1
FX FY FZ MX MY MZ
NODE Load Case N. N. N. N.m. N.m. N.m.
10 Rigid ANC
1(OPE) 79
- -5301 1917 -2400 - 5472 501
33 Rigid +Y
1(OPE) 0 -10938 0 0 0 0
37 Rigid +Y
1(OPE) 0 -4794 0 0 0 0
43
1(OPE)
Rigid +Y
0 0 0 0 0 0
(
45 Rigid +Y
0
1(OPE) 0 -29880 0 0 0
57 Rigid +Y
MOPE) 0 -24813 0 0 0 0
77 Rigid +Y
1(OPE) 0 0 0 0 0 0
90 Rigid ANC
MOPE) 79 -2897 -1917 -1291 -5940 -111
The operating case however still shows lift zero load at node 77, and now also zero load at node 43 .
Checking the displacements also confirms this; there is still a positive displacement at nodes 77 and
now at 43. Node 50 is still moving downwards, although only 15mm now.

DX DY DZ RX RY RZ
40 4.620 11.362 -24.859 -0.0949 0.0120 -0.0395

43 4.521 11.097 -24.616 -0.0997 0.0119 -0.0398
45 -0.099 -0.000 -6.613 -0.2157 0.0094 -0.0473
-0.0422
SO
57
-7.328
-7.382
-15.792
-0.000
19.348
7.847
0.1130
0.0699 -
0.0030
0.0032 -0.0343
60 -7.373 0.164 7.569 0.0597 -0.0035 -0.0341
70 -7.342 0.686 6.626 0.0583 -0.0035 -0.0341
77 -6.916 0.803 0.103 -0.0224 -0.0108 -0.0296
(
(
IlMItKOKAPH
*
Supt 01
We will attempt to further distribute the thermal expansion of the riser by adding a third restraint,
located near the bottom.
Break element 45-50 and create node 47. Locate node 47 6000mm below node 45 and locate a +Y
support at this point.
Rerun the analysis and check that the stress levels have not been adversely affected.
As before, view the SUS and OPE loads on the restraints to see how the new restraint has affected
the analysis .

INTERGRAPH
Supt 01
84

CASE 2 (SUS) W+Pl
FX FY FZ MX MY MZ
NODE Load Case M N. N.m. N.m. N.m.
10 Rigid ANC
2(SUS) 2 -6442 -31 -927 77 -2584
33 Rigid +Y
2(SUS) 0 -7336 0 0 0 0
37 Rigid +Y
2(SUS) 0 -12056 0 0 0 0
43 Rigid +Y
2(SUS) 0
- 8815 0 0 0 0
45 Rigid +Y
2(SUS) 0 -9263 0 0 0 0
47 Rigid +Y
2(SUS) 0 -12653 0 0 0 0
57 Rigid +Y
2(SUS) 0
-13683 0 0 0 0
77 Rigid +Y
2(SUS) 0 -4630 0 0 0 0
The sustained report shows that we have further improved the weight distribution among the
restraints .

(
INTERGRAPH
Supt 01

v,
NODE Load
T
Case FX FY
.
.
FZ
N.
MX
N.m.
MY
N.m.
MZ
N.m.
10 Rigid ANC
1(OPE) 90- -4802 1929
-3681
-
5372 2242
33 Rigid +Y
1(OPE) 0 -13253 0 0
37 Rigid +Y
1(OPE) 0 -544 0 0 0
43 Rigid +Y
1(OPE) 0 0 0 0
45 Rigid +Y
l(OPE) 0 0 0 0
47 Rigid +Y
1(OPE) 0 -34679 0 0
57 Rigid +Y
1(OPE) 0 -19557 0 0
77 Rigid +Y
l(OPE) 0 -1767 0 0
.
The Operating case now shows a negative load on restraint at node 77 There is no more lift off here
at 77. However the operating loads at node 43 and 45 are now zero. All the thermal expansion that
was going downwards with only the one restraint at the top of the riser has now been forced
upwards instead, causing the pipe to lift off at the top of the riser ( 43 and 45).
The displacements report confirms this

CASE 1 (OPE) W +T1+ P 1
DX DY DZ RX RY RZ
NODE deg.
mm. mm. mm. deg. deg.
40 3.629 22.414 -25.561 -0.0310 0.0168 -0.0352

43 3.541 22.150 -25.476 -0.0371 0.0167 -0.0355
45 -0.560 11.060 -11.186 -0.2071 0.0143 -0.0415
47 -4.881 -0.000 12.097 -0.2089 0.0118 -0.0397
50 -6.688 -5.410 19.377 -0.0006 0.0069 -0.0310
57 -7.142 -0.000 7.876 0.0290 0.0001 - o.oiee
60 -7.142 0.064 7.598 0.0231 -0.0002 -0.0185
70 -7.140 0.264 6.654 0.0223 -0.0002 -0.0185
77 -6.895 -0.000 0.132 -0.0142 -0.0082 -0.0115

INTERGRAP
*
H
Supt 01
86
The pipe is lifting off 22mm at the top of the riser.
The 3D plot can also confirm the situation:
~ r*
So we have a situation where we are supporting the weight of the system adequately in the SUS load
case, but we have an issue with the thermal expansion. If we replace the rigid +Y restraints along
the riser with Variable Spring Hangers (VSH ), these hangers should allow thermal growth whilst also
supporting the required weight for the SUS condition.

INTERGRAPH
*
Supt 01
Place Spring Hangers

Return to the input at locate element 40-43. Remove the restraint at node 43 by double clicking the
restraint check box.
.
Place a hanger here instead Double click the Hangers check box
Restraints Displacements
0Hangers Flange Checks
Nozzle Rex. Nozzle Lmt Check
.
Select the Hanger table as Carpenter & Paterson Carpenter & Paterson are a UK manufacturer
whose database of available spring hangers is programmed into CAESAR II. CAESAR II will
automatically calculate the required load and movement at the location, and then review the
database to select an appropriate spring for the calculated load and movements.
.
Notice that 2 hangers are located at this location also The graphics will not change in CAESAR II, but
this will locate 2 hangers at this location, and the selected spring will be based upon this shared load.
Node: 43 Cnode:
Design Data
Hanger Table 16 ' Carpenter & Pate
n
Extended Range Cold Load Hot Load Centered
Available Space (neg for can)

Allowable Load Variation ('/ ) . 125.000
Rigid Support Displacement Criteria
Mny AHnwpH Trm/pl I imit
I No. Hangers at Location 2

rillbW Short Range Springs
'
Operating Load (Total at Loc.):

0
Hanger Hardware Weight
Multiple Load Case Design Option:

Free Restraint at Node :
Free Restraint at Node:
Free Code:

Predefined Hanger Data
Spring Rate:
-
ft
? Theoretical Cold (Installation) Load:
or
Constant Effort Support Load:
4
Error check the model. You should now notice two further notes during the error check.
p <b
1
Q|I S
*
Start Run
(
(
INTERGRAPH
Supt 01
83
Number of HANGERS in this job = 1

Number of HANGERS to design 1
Number of Pre-Designed HANGERS - 0
The LOAD CASES below should be defined at analysis

level to properly perform the HANGER DESIGN:
COMBINATION LOAD CASE 1 WEIGHT LOADS
COMBINATION LOAD CASE 2 SPR. DESIGN OPERATING CASE # 1
COMBINATION LOAD CASE 3...Any cases with the designed
hangers installed .
The first not simply shows the number of hangers in the job, and how many of these hangers will be
designed by CAESAR II at run time.
The second message states that new load case combinations are required for the hanger design. A
load case for weight loads is required, so that CAESAR II knows how much weight the hanger(s) need
to support. Secondly, a hanger design operating case is required. This case determines the thermal
expansion at each restraint location to determine the movement at the spring hanger locations as
well. The values of weight from the previous weight load case are used. These two cases together
are used by CAESAR M's spring selection algorithm to select the appropriate spring from the in-built
catalogue.
Access the load case editor to create these new load cases .
i
l - Q
4S i i i
Edit Static Load Cases

1
j
Start Static Analysis

ms: 0 Not
Click the Recommend button in the load case editor. CAESAR II knows that there are hangers
present that require designing, so will recommend the correct load cases for hanger design - cases 1
and 2.
Cos Load Case Description

1 W(HGR) WEIGHT FOR HANGER LOADS
2 W+Tl +P1(HGR) OPERATING FORHANGERTRAVEL
3 WT1+P1 *H(OPE) OPERATING CASE CONDITION 1
A W+Pl +H(SUS) SUSTAINED CASE CONDITION 1
5 L3-L4(EXP) EXPANSION CASE CONDITION 1
Accept these cases. Note the stress type forthese cases are HGR type. The results for these hanger
cases are supressed by default (theses are pre-analysis cases and the figures do not actually mean
anything other than for the spring hanger selection).
Case 1W (HGR)
This case performs a Weight Analysis only with all support locations as rigid restraints. This tells the
spring selection algorithm how much weight needs to be supported at each location (usually in the
Operating condition)

INTERGRAPH
Supt 01
89
Case 2 W+T1+P1(HGR )
The case uses the support weight values derived from case 1as upward forces for an Expansion
analysis. That is, the values of W cancel each other out (support load versus actual weight), and the
system is then subject to temperature T1in order to establish the thermal movement at each
restraint location. Given the Weight to be supported and the thermal movement at the same
location, the spring and its associated stiffness values can be selected and incorporated into the
subsequent load cases.
Run the analysis
; B Si c/
Load Cose Editor i

Run the Analysis j,
(
CAESAR II will have selected and sized a spring hanger during the analysis. Check the Hanger Table
with text to view the hanger properties of the selected hanger.
General Computed Results

HanqerTable
Input Echo
Miscellaneous Data
Load Case Report
Warnings
CAESAR II HANGER REPORT (TABLE DATA FROM DESIGN RUNS)
THEORETICAL ACTUAL
NO. FIG. VERTICAL HOT INSTALLED INSTALLED SPRING HORIZONTAL
NODE REQD NO. SIZE MOVEMENT LOAD LOAD LOAD RATE MOVEMENT
43
+ +
2 DV70
+
11
+ (mm.) + (N. ) + (N. ) + (N.
22.234 6723.
-
8046.
) (KN./mm.) (mm.)-
0. 0. 25.725
CARPNTRSPATRSON LOAD VARIATION = 20%
** VARIABLE SUPPORT SPRING DESIGNED MID RANGE
MINIMUM ALLOWED SINGLE SPRING LOAD (N. ) 5292.986
MAXIMUM ALLOWED SINGLE SPRING LOAD (N. ) 9460.985
RECOMMENDED INSTALLATION CLEARANCE (mm.) 305.054
+ + + + + + + + +
As can be seen, CAESAR II has determined that the hanger will need to support a hot load (i.e. OPE)
of 6723N. There are two springs at this location, so this 6723N is the total load shared between two
supports (i.e. the total load is 6723 N x 2 ) .
CAESAR has taken these properties and browsed the inbuilt Carpenter & Paterson database and
selected a DV70 Size 11 spring.
Verify the sustained and expansion stresses - these should still be acceptable ( 13% and 19%).
Now check the OPE restraint loads.

INTERGRAPH
Supt 01
90

CASE 3 (OPE) W+T1+P1+H
FZ MX MY MZ
NODE Load Case .
N . .
N m . .
N m .
N m .
10 Rigid ANC
3(OPE) -90 -4797 1932 -3690 - 5381 2256
33 Rigid +Y
3(OPE) 0 -13272 0 0
37 Rigid +Y
3(OPE) 0 -510 0 0
43 Prog Design VSH

3(OPE) 0 -13447 0 0
45 Rigid +Y
3(OPE) 0 0 0 0
47 Rigid +Y
3(OPE) 0 -21251 0 0
57 Rigid +Y
3(OPE) 0 -19559 0 0
The hanger at node 43 is now taking load. This load is 13447N ( which is 6723N x 2 ), however there is
still no load being taken at node 45.
Return to the input and replace the rigid +Y support at node 45 with a spring hanger. As before,
select the Carpenter & Paterson catalogue, and place 2 hangers at this location before re-running
the analysis.
As before the SUS and EXP stresses are acceptable.
The OPE case Restraint summary now shows that all the restraints are taking load. The new spring
hanger is taking some of the load of the riser - this is now distributed evenly.

INTERGRAPH
0
Supt 01
NODE Load Case FX FY F2 MX MY MZ

N. N. N. N.m. N.m. N.m.
33 Rigid +Y
3(OPE) 0 -13272 0 0 0 0
37 Rigid +Y
3(OPE) 0 -510 0 0 0 0
43 Prog Design VSH

3(OPE) 0 -0815 0 0 0 0
45 Prog Design VSH

3(OPE) 0 -9263 0 0 0 0
47 Rigid +Y
3(OPE) 0 -16620 0 0 0 0
57 Rigid +Y
3(OPE) 0 -19559 0 0 0 0
77 Rigid +Y
3(OPE) 0 -1766 0 0
90 Rigid ANC
3(OPE) 90 -4022 -1932 -720 -5877 3759
CAESAR II has again run the two hanger cases and used the results from these to select appropriate
hangers for placing at the two hanger locations. These can be seen from the Hanger Table with text
CAESAR II HANGER REPORT (TABLE DATA FROM DESIGN RUNS)
THEORETICAL ACTUAL
NO.FIG. VERTICAL HOT INSTALLED INSTALLED SPRING HORIZONTAL
43
+ +
2 DV70
+
9 22.234 4408.
--
+ (nun.) + (N. ) + (N. )
5186.
-
+ (N. ) (KN./mm.) (mm. )
0. 0. 25.725
-
CARPNTR&PATRSON LOAD VARIATION = 18%
** VARIABLE SUPPORT SPRING DESIGNED MID RANGE
H + ( 1 i 1 1 ! 1-
45 2 82 10 11.117 4631. 5644. 0. 0. 11.220
ANVIL LOAD VARIATION = 22%
** VARIABLE SUPPORT SPRING DESIGNED SHORT RANGE
+ + + + + + + + +

/>
t
INTERGRS PH
Flange Analysis
Flange Analysis
Inline Analysis
This simple exercise will demonstrate the flange analysis capabilities in CAESAR II
Create a new model as shown below :
Diameter: 12
Schedule : STD
Material: A106 B
Tl: 150C
PI: 12 bars
No Fluid Density or Corrosion

INTERGRAPH
*
Flange Analysis EE
Complete the model using the table below. When placing the flanges ( 40-50 and 80-90), use the
Vlave Flange database and select a Flange Pair, and activate the Flange Check.
e Database: CADWORX.DAT
Rigid Type End Type Class

GATE Islftr nan
GLOBE NOFLG 300
CHECK THREAD 600
CONTRL SOCKET 800
BALL 900
PLUG 1500
BTRFLY 2500
FLANGE
Whole element From end To end Both ends
Flange - Valve - Flange
0 Activate Flange Check
OK Cancel
Element Length/ Direction Additional

10-20 3000mm DX ANC at node 10
Bend at node 20
20-30 1000mm DY Bend at node 30
30-40 1000mm DZ
40-50 231.775mm DZ Flange Pair from Valve Flange
Database
Flange Checks activated
50-60 800mm DZ Bend at node 60
60-70 1200mm DY Bend at node 70
70-80 1000mm DX
80-90 231.775mm Flange Pair from Valve Flange
Database
Flange Checks activated
90-100 600 mm ANC at node 100
The complete model should look like the one below (Viewed in a SW Iso View rather than the default
SE Iso View).

INTERGRAPH
Flange Analysis
94
i*
K
Now we will set up the flange checks.
There are two methods of performing inline Flange checks in CAESAR II
-
Peq Kellogg Equivalent Pressure Method
-
NC 3658.3 - ASME B&PVC Section III Subsection NC-3658.3 Method
We have two flange pairs so we will perform one check on each flange pair .
Kellogg Equivalent Pressure Method
Element 40 50 we will use the Kellogg Equivalent Pressure Method:
16M 4F
peq = + PD = Pressure Rating
Where:
Peq = equivalent pressure (for checking against flange rating)
M = bending moment on flange
G = diameter of effective gasket reaction
F = axial force on flange
PD = Design Pressure
Select Element 40-50.
Notice that the flange checks box is now ticked, single click on this tick box to view the Flanges
auxiliary window.
First ensure that the flange check will be performed on Both ends of the element, and select the Peq
radio button.

(
INTERGRAPH
*
Flange Analysis
From: To. Both: o
I [Peqil o NC-3658.3:
Next we need to input the flange and gasket properties, as needed in the equation above for the
check .
| Read from Fils ]
Flange Class / Grade.
Gasket Diameter. G
Temperatu Pressure |
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
The Gasket effective diameter G must be entered, as must the flange temperature/pressure rating.
This can be entered as a function of temperature {for a particular material grade). These values can
be entered manually, or can be looked up and imported from the inbuilt database using the Read
from File... button.
Use this Read from File button to select ASME -2003 150 # Group 1.1 Material Flange:
lljEHtsiai iaATluafifefltitita
"
iTASME-1996
B ASME-2003
ll 75
150
1.2
This will pull through the data into the appropriate fields.

INTERGRAPH
Flange Analysis
Flange Class /Grade ASME-2003-150-1 1
Gasket Diameter. G 357 251
Temperatu Pressure
1 37 8 19 6
2 93 3 17 9
3 148 9 15 9
4 204 5 13 8
5 260 0 11 7
6 315 6 97
7 343 4 86
8 371 1 76
9 398 9 65
10 426 7 55
11 454 5 45
12 482 3 34
13 510 0 24 (v
NC - 3658.3 Method
Element 80-90 will have the check performed using the NC-3658.3 Method.
S = 36,000 x (C A{jX 3 1 2 b ) = Min( Sy , 36000) For a non-OCC Load Case

*
= 2 x Min( Sy , 36000) For an OCC Load Case

S = 36,000 x (CA '*12 S )
Note that in SI units, the constants differ.

36,000 should be 248.22
3125 should be 21.6
S = flange stress
MfS = bending or torsional moment (whichever is greater) acting on the flange, developed during
a non-Occasional Load Case
Mfd = bending or torsional moment ( whichever is greater ) acting on the flange, developed during
an Occasional Load Case
Sy = yield strength of flange material at design temperature; ( where Sy, given in psi, shall not
be taken as greater than 36,000 psi)
C = bolt circle diameter
Ab = total cross sectional area of bolts
Again the Flange checks box should already be ticked. Again click on this box to view the flange
auxiliary module. Also as before, ensure that the flange check is performed at both ends.
This time, select the NC-3685.3 radio button.
From: To: Both o
Peq NC-3658 3:
V
INTERGRAPH
*
Flange Analysis
This updates the flange window to display the required data for the NC-3658.3 method.
Bolt Area Ab: 0.000
.
Bolt Circle Diameter C: 0.000
.
Flange Yield Strength SYC 0.000
.
Range Yield Strength SY1 0.000
.
Range Yield Strength SY2 0000
.
Range Yield Strength. SY4 0.000

(
.
Range Yield Strength. SY8 0 000

,
Flange Yield Strength, SY9 . 0000
For a 12 B16.5 Flange, the bolt circle diameter is 432mm
The bolt area for 12 x 22mm bolts is:
x (222 x 12) = 4561mm2

4
The yield strength we will use is 290MPa. You must enter the yield strength for cold ( ambient) (SYC)
. .
and for all the operating temperatures For this exercise we will use 290MPa in all cases Even if you
have only one operating temperature, you must enter a yield strength in all temperature fields,
otherwise you will see errors during an error check:
Message Element/
Number Node Number
1 ERROR 221E 80- 90 On element 80 to 90 the flange SY2 entry must be
greater than zero.
Enter in the data derived above.

INTERGRAPH
*
Flange Analysis
98
Bolt Area. Ab: 4516.000
.
Bolt Circle Diameter O 432000
.
Flange Yield Strength SYC 290000
Flange Yield StrengthSY1 290000
Flange Yield Strength. SY2 290.000
.
Range Yield Strength SY3. 290.000
Flange Yield Strength. SY4 290.000
.
Flange Yield Strength SY5 290000
Range Yield Strength. SYB 290.000
.
Flange Yield Strength SY7 290000
Flange Yield Strength. SY8: 290000
.
Range Yield Strength SY9: 290.000
Now error check the model. You should see no errors or warnings, just the C of G report.
Errors and Warnings

*
:Errors: o Warnings: 0 Notes: 1 ,
Message Element/ Message Text

Message Type
Number Node Number
1 MOTE

N . mm . nun . nun .
Pipe 7070.7 2798.4 1029.6 1002.0
Insulation O.0 0.0 0.0 0.0
Refractory 0.0 0.0 0.0 0.0
Fluid 0.0 0.0 0.0 0.0
Pipe+Ins+Rfrty 7078.7 2798.4 1029.6 1002.0
Pipe+Fluid 7078.7 2798.4 1029.6 1002.0
Pipe+Ins+Rfrty+Fld 7070.7 2790.4 1029.6 1002.0
Run the analysis with the default load cases.
After the analysis has completed view the Peq and the NC-3658.3 reports.
Load Cases Analyzed Standard Reports c
1(ORE) W+T1+P1 Displacements 1
Restraints
2 (SUS) W +Pl Restraints Extended
3 (EXP) L3=L1- L2 Local Restraints \
Restraint Summary
Nozzle Check

Glnhnl Flpmffnt Fnrrp.s FxtRnriRrt

INTERGRAPH
Flange Analysis
99
The reports all state that the Output is disabled and there is no data to display .
FLANGE PEQ REPORT: Flange ( Equiv Pressure Method )
CASE 1 (OPE) W+T1 +P1
Output disabled for field "Axial Force

Output disabled for field "Bending Moment
Output disabled for field "G/C"
Output disabled for field "P Equivalent"
Output disabled for field "Rating Temperature"
Output disabled for field "Allowable Pressure /Stress
Output disabled for field "Ratio"
Report Contains No Data to Display
The reason for this is Flange evaluation is based on a specific load case temperature. To evaluate the
flanges in a model, use the Load Case Options tab of the Static Load Case Editor to specify which
operating temperature the flanges should be evaluated to.
This is a common issue with users running these inline flange checks. To resolve this, simply access
the load case editor:
Load Case Editor Load Case Options Wind Loads Wave Loads
Elbow Elbow Flange

Stiffening Friction Occ Load
Load Case Name Stiffening Analysis
Pressure Elastic Multiplier Factor
Temperature
Modulus
L1 OPERATING CASE CONDITION 1 PMax EC 1 0000 MB
L2 SUSTAINED CASE CONDITION 1 PMax EC 1 0000
L3 EXPANSION CASE CONDITION 1 PMax EC
T3
T4
T5
Access the Load Case Options tab and scroll to the right. In the very last column is Flange Analysis
Temperature. Here you can ( and must) specifiy a temperature, and temperature T1to T9 can be
chosen, or you can select Tmax orTamb to use the highest or Ambient temperature.
For our analysis, select temperature T1in the OPE case and rerun the analysis.

INTERGRA
*
PH
Flange Analysis
100
The PEQ analysis fails at node 50 and is also >90% at node 40.
FLANGE PEQ REPORT: Flange (Equiv Pressure Method)

P Rating Allowable
Axial Bending
G/C Temperatur Pressure Ratio
NODE Force Moment Equivalent e %
N. N.m. mm. bars /Stress
C
40 13018 1316 357.25 14.77 150.00 15.82 93.37
50 13018 3114 357.25 16.78 150.00 15.82 106.07 *
The NC-3658.3 analysis passes at both flanges
-
FLANGE NC 3658.3 REPORT: Flange (NC-3658.3 Method)
Torsion Bending Flange Allowable Ratio

G/C AB Stress Pressure
NODE Moment Moment
mm. sq.mm. %
N.m. N.m. N./sq.mm. /Stress
B0 6318 5180 432.00 4516.000 37.31 248.21 15.03

90 6318 6766 432.00 4516.000 39.96 248.21 16.10
CAESAR II also includes a more detailed flange analysis module. We can use this module to refine
the calculation.
t
INTERGRAPH
"
Flange Analysis
Flange Analysis Module

There have been primarily two different ways to calculate stress and one way to estimate leakage
for flanges that have received general application over the past 20 years. The stress calculation
methods are from the following sources:
ASME Section VIII
ANSI B16.5 Rating Tables
The leakage calculations were also based on the B16.5 rating table approach. Leakage is a function
.
of the relative stiffnesses of the flange; gasket and bolting Using the B16.5 estimated stress
calculations to predict leakage does not consider the gasket type, stiffness of the flange, or the
stiffness of the bolting. Using B16.5 to estimate leakage makes the tendency to leak proportional to
..
the allowable stress in the flange, i e a flange with a higher allowable will be able to resist higher
moments without leakage. Leakage is very weakly tied to allowable stress, if at all.
The CAESAR II Flange Leakage Calculation is our first attempt to improve upon the solution of this
difficult analysis problem. Equations were written to model the flexibility of the annular plate that is
the flange, and its ability to rotate under moment, axial force, and pressure. The results compare
.
favourably with three dimensional finite element analysis of the flange junction These correlations
assume that the distance between the inside diameter of the flange and the center of the effective
gasket loading diameter is smaller than the distance between the effective gasket loading diameter
and the bolt circle diameter, i.e. that (G-ID) < ( BC-G), where, G is the effective gasket loading
diameter, ID is the inside diameter of the flange, and BC is the diameter of the bolt circle.
Several trends have been noticed as flange calculations have been made:
The thinner the flange, the greater the tendency to leak.
Larger diameter flanges have a greater tendency to leak.
Stiffer gaskets have a greater tendency to leak .
Leakage is a function of bolt tightening stress.

INTERGRAPH
Flange Analysis
102
Return back to the CAESAR II Main Window and access the Flanges module from the Analysis menu
Anahrsts pffiffllWTHHRSSlf
11 D <D 0 50
Statics
Dynamics
SIFs Intersections
SIFs @ Bends
WRC 107/297
Flanges
B31 G .
Expansion Joint Rating
AISC
Create a new file.
The Flanges module has various tabs where the data is input.
We will input the same data and verify this flange.
Flange Bolls and Gasket Material Data j Loads
Flange Type
Integral Weld Neck Integral Slip On Integral Ring Loose Slip On

Loose Ring
IS
Lap Joint
sn
Blind
o 0
Reverse
c m 0
Flange Class
Flange Grade
Flange Outside Diameter [A]

Flange Inside Diameter [8] |
Flange Thickness [t]
Range Face OD or Lapjt cnt OD.

Range Face ID or Lapjt cnt ID
Small End Hub Thickness [gO]

Large End Hub Thickness [gl ]
Hub Length [h]
As before, our flange is a 12 diameter, class 150 flange. This is also an Integral Weld neck flange.
For a weld neck flange, this data input can be simplified using the Lookup function Specify the .
flange type as Integral Weld Neck and hit CTRL+F

INTERGRAPH
*
Flange Analysis
103
Range Bolts and Gasket Matenal Date
Integral Weld Neck
Loosening
B
After hitting CTRL+F the Flange Dimension lookup dialog appears.
Specify a 12 nominal diameter and Flange class 150 and click OK
IflteiimafflliiTdiUtoiUktTili
Note gasket facing & reaction diameter are approximate
Dimensions are forWELD NECK flanges only.
Nominal Diameter 12 (inches)
Range Class: 150 .

(i.e.150.300 ...)
This will fill in most of the data. We are left with requiring the following fields. Fill these in as shown
below:
Flange Grade: 1.1

Flange Face OD: 381mm
Flange Face ID: 304.8mm
Flange Class : 150

Flange Grade: 11000
Range Outside Diameter (A] 4B2 BQQQ

Flange Inside Diameter [0] 304 8000
Flange Thickness [t] 30 2260
Flange Face OD or Lapjt cnt OD 381 0000

Flange Face ID or Lapjt cnt ID 304 8000
Small End Hub Thickness [gO] 9 5250

Large End Hub Thickness [g1]: 30 2280
Hub Length [h]: 182.5500

f

INTERGRAPH
0
Flange Analysis
104
Now move on to the Bolts and Gasket tab. Some of the bolt information will be filled in
automatically from the lookup .
The Bolt initial tightening stress we will use is 216MPa
Bolling Information
Bolt Circle Diameter 431.8000
Number of Bolts: 12.0000
Bolt Diameter 22.2250
Bolt Initial Tightening Stress: 216.0000
The Gasket information is as below:
Gasket Information
Gasket Outer Diameter:1377.0000
Gasket Inner Diameter ph 0.0000

Uncompressed Gasket Thickness 11.6000
Effective Gasket Modulus 2500.0000
Leak Pressure Ratio [m] 3 0000
[
Gasket Seating Stress [y] 69.0000
Nubbin Widlh (or Ring Joint Width)
Facing Sketch 1.0000
Facing Column 2.0000
Next Move on to the Material Data tab.
First enter in the design temperature as 150C
Now we can pick the materials and pull through the data from the material database.
The Flange Material is SA-105. The Bolt Material is SA-193 B7.
Use the Browse button to select these materials from the Material database.
Range Material SA-105 Brow]sj ..
Bolt Material: SA-193 B7 | Browse...
Material Selection
Material Name Occurrence Composition Form UNS Number *
Carbon Steel .. Forgings K03504 |S |
[ I SA-10GA 1 Carbon Steel ... Smls. pipe K02501
Once a material is clicked, the material properties show up
(
INTERGRAPH0
Flange Analysis
105
Material Name: |SA-105 Temp. C Stress N. / sq.mm, Temp. C Stress N / sq. mm

Occurrence: c 137.7822 | 1137 892 ( { 482 262 1
[510 042 1
461938
I
Chemical Composition - { 65.5622 | ( 137.892 27 5784
I
Product Form: Forgings 93.3422 | ( 137.092 | 537 822
1 |17 2365 I
UNS: K03504 (121.122 | |l37.892 [ 565 602 ]l I
Class /Thickness: I 1140.902 | |137.692 { 1593 362 1 l I
P Number Thickness: 131.75 mm. |l76.682 | |137.892 Z] [ 621 162 ] I
P Number III { 204.462 | |l37.892 648.942 ] |
I
Group Number El { 232.242 | (136.513 ! [ 676 722 ] l
I
704502 ]
Minimum Tensile Stress 482622 N./ sq.mm. |260.022 | 1135.134 | l I
N./ sq.mm. |2B7.B02 732 282 ]
Minimum Yield Stress: j 246.206 | 1130.997 | l I
760 062 ] l
External Pressure Curve |CS-2 { 315.582 | |126.861 |
I
TEMA Number
El 343.362 | 1122.724 7B7.B42 ]
l I
Material Density. |7833 44 kg / cu.m. [ 371.142 | |l18.587 | . 815.622 ]
l I
I 2 1398.922 | 10204 1043 402 ] l I
Non Normalized Curve #

E: 1426.702 | 182.7352 671.182 ] |

I
] l
Normalized Curve #:
[?54 482 | 641198 ( 698.962 |
l
| OK |i Cancel
Complete the remaining data as shown
Flange Material SA-105 Browse. .
Bolt Material SA-193 B7 | Browse... [
Design Temperature 150.0000

Range Allowable @DesignTemperature. 137 8920
Range Allowable @AmbientTemperature: 137 8920
Range Modulus of Elasticity @Design 195040 0000
Range Modulus of Elasticity Ambient 203390.0000
BoltAllowable Design Temperature: 129.6185
Bolt Allowable Ambient Temperature 129.6185
Range Allowable Stress Multiplier 1.5000
BoltAllowable Stress Multiplier (VIIIDIV 2 4-141) 2.0000

INTERG
"
RAPH
Flange Analysis
106
Finally select the Loads tab to enter in the loads.
The loads from previously on the failing flange were
FLANGE PEQ REPORT: Flange (Equiv Pressure Method)

P
Rating Allowable
Axial Bending G/C Temperatur Ratio
NODE Force Moment Equivalent Pressure %
mm. bars e /Stress
N. N.m. c
40 13018 1316 357.25 14.77 150.00 15.82 93.37
50 13018 3114 357.25 16.78 150.00 15.82 106.07
Enter in the axial force and bending moment, along with the 12 bar pressure
External Loads
Design Pressure [P] 12.0000
Axial Force (Optional) 13018 0000
Bending Moment (Optional) 31140000
Now run the analysis.
On review of the results, it can be seen that there is a failing in our flange .
A * indicates that this item has failed.
Flange ] Bolts and Gasket Material Data | Loads

J Output [
OPERATING ALLOW SEATING ALLOW
Longitudinal Hub 51 207 103 207

Radial Flange ... 75 207 150 138
Tangential Flange 21 207 42 138
Maximum Average . 63 138 126 138
Bolting 77 259 246 130
Indicates Failure for an item.
This can be fixed quite easily by changing our flange to a 300# flange
Return back to the Flange tab and choose to lookup the flange properties again ( CTRL + F ) This time .
enter 12 nominal size, but specify a 300# flange

(
INTERGRAPH
*
Flange Analysis
107
* 111 It
Note gasket facing & reaction diameter are approximate.

Dimensions ore for WELD NECK flanges only.
Nominal Qiometer 12 (inches)
Flange Class - 300 fe

(i.e.150.30( .)
The flange and bolt properties will update
Flange Class 300

Flange Grade : 1.1000
Flange Outside Diameter [A]; 520.7000

Flange Inside Diameter [B]: 3(M.8000
Flange Thickness [t]: |49.27B 0
Flange Face OD orLapjl cnt OD: 381,0000

Range Face ID or Lapjt cnt ID: 304.8000
Small End Hub Thickness [g0]: 9.5250

Large End Hub Thickness [g1]: 34.9250
Hub Length [h]: 79.2480
Bolting Information
Bolt Circle Diameter 450.8500
Number of Bolts: 16.0000
Bolt Diameter 28.5750
Bolt Initial Tightening Stress: 216.0000
Gasket Information
Re run the analysis.
There should be now no failures with a 300# flange
Range Bolts and Gasket | Material Data ] Loads J Output
OPERATING ALLOW SEATING ALLOW
Longitudinal Hub 30 207 94 207

Radial Flange .... 26 207 81 138
Tangential Flange 16 207 49 138
Maximum Average . 28 138 87 138
Bolting 33 259 106 130
Indicates Failure for an item.
/
K
INTERGR
*
APH
Turbo
108
Turbo
This exercise will build upon knowledge we have gained so far, and introduce the following new
features.
Combining Pipe Models

Rigid Construction Elements
CNode Connections
NEMA SM 23 Analysis
12 * SCH 00 INLET HEADER

8 * SCH 40 EXHAUST
4 * SCH 00 INLET 5
ziy 5 o
& g
150 FLG GATE

150 FLG GATE '
-BASE TO NOZZLE
-
DX = 150
DY *500
B'x 6 * CDNC REDUCER - -
Z = 50
(152 LG)
NOZZLE TO BASE USE B31.3

DXslQO MATERIAL = A-I06-B
Y -
DY = 300
DZ =- 450
50mm CALCIUM SILICATE INS.
.
INLET
TEMPERATURE -
PRESSURE = 12 BAR
200 C
--
EXHAUST:
z x TEMPERTURC
PRESSURE
150 C
5 BAR
Notes:
Tee types are type 3 - Welding
Fluid Density - leave this blank (assumed 0.00) - this could be reviewed in a steam table, but
leave blank for this exercise.
The model is shown above and is also supplied in the hand-out in a larger format. As can be seen,
this is an inlet and exhaust on a turbine. The turbine itself is anchored to the floor at the anchor
point specified.
To keep modelling simple, we can model the inlet and exhaust as two separate models. These two
models can be combined into a single model later - there is a common location at the turbine
anchor point.
We will model this common anchor point location as node number 5. However, we will come back
and model this point last.
Copyright 2011Intergraph CADWorx & Analysis Solutions

c
INTERGRAPH
*
Turbo
109
Model Inlet
Model the inlet pipework, on the first element; change 10 to 20 to 11 to 20. Begin at node 11, the
flange connection to the turbine nozzle, as shown below. Note that node 11 also has an anchor
attached.
50
11
///// / /
40Y 30
20
Once the inlet piping is complete, return to the first element, 11 to 20. We will now insert an
.
element before 11 to 20, numbered 5 to 10. Node 5 will be the turbine anchor location Node 10
will be connected to the anchor at node 11. We will connect these via CNode connections.
As there is an anchor at node 11, this node is fixed in all 6 degrees of freedom. However, the nozzle
connection on the turbine will undergo some movement due to the thermal expansion of the
turbine. Recall previously that we had a similar situation where displacements were specified to
.
account for a similar situation in PIPE 1for the vessel thermal expansion In this case, we do not
know what the thermal expansion is here so we cannot enter the displacements. To apply the
displacements to the nozzle point we will add in an element from the nozzle to the turbine base .
This will be a rigid element with zero weight, and it will have temperature applied (so it will undergo
.
thermal expansion) This element will also be anchored at the turbine base.
If however we specified this as 5-11 for example, nodes 5 and 11 are both anchored, so cannot move
and all that will happen is we will obtain large forces at nodes 5 and 11. We need a way of
connecting this rigid construction element to node 11 which will allow node 11 to move due to the
expansion of the construction element, but still be fixed as far as the rest of the piping is concerned.
This can be achieved in CAESAR II this using CNodes. A CNode will allow the anchor at node 11 to be
connected to another node indirectly . Essentially, both these points will be at the same location,
but CAESAR II will see these points as separate nodes. Therefore what will happen is that as element
5-10 expands, node 11 will act as an anchor, but as it is connected to node 10, node 11 will move to
wherever node 10 moves to, while still acting as an anchor.

INTERGRA
*
PH
Turbo
110
11

//// ///
/77777777 Nodes 10 and 11 are the same point in space .

Select element 11-20. First specify a CNode on the anchor at node 11; the CNode will be node 10.
Node: 11 CNode: 10|
Type: ANC Gap
Stif: Mu
Next use the Insert function to insert an element before this element.
Insert Element
SI Classic Piping Input Insert new element

Before
current element
From After
t
Insert OK Cancel
Insert a new element
Change the node numbers to 5 to 10

From: 5
Name
To: ( l O
Fill in the DX, DY, DZ fields as shown on the isometric sketch
DX -150 000 mm
DY: 500 000 mm
DZ: -50 000 mm
(Offsets]
This is a rigid element, but leave the weight blank in this case. Also add an anchor at node 5.

(
INTERGRAPH
'
Turbo
f
The zero weight rigid will be inserted and connected to node 11 as above. We now need to specify
the temperature for the rigid, as this will undergo thermal expansion .
Select element 5-10 and double click the on the temperature/pressure section to tear off the
Operating Conditions box. Uncheck the Propagate parameters box to ensure that the data entered
.
here is only entered on this one element, and not the whole model Enter 200C for T1and make
sure that no pressure is specified.
Edit Operating Conditions ?

*
7
...
Thermal
Temperature Expansion Pressure
1 200 0000 0.002190 n

H
3 1 II
A
T
8
9
I
Hydro
Propagate Parameter
J
INTERGRAPH
0
Turbo
Check that this has been specified correctly, by using the Show Pressure graphical tool.
1 * & fei ae
. <
L>
Show Pressures
Display PI.
r a i 1*0 SO 90 SB L5 :J
put
ZD DNam Pressure 1
ZD Highlight Pressure 1
The rigid construction element should show as unspecified, and the rest of the model should show
as 12 bars.
Legend
Pressure 1 (bars )
Unspecified M 255; 0; 102
12.0000 I~1153; 102; 255
The inlet is now complete.
Error Check the file - verify that the centre of gravity report gives values similar to those shown
below.

Total Wght
N.
Pipe : 10443.5
Insulation : 1099.0
Refractory : 0.0
Fluid : 0.0
Pipe+ Ins+ Rfrty : 11542.5
Pipe +Fluid : 10443.5
Pipe+ Ins+ Rfrty+Fld : 11542.5
Save the file and using the same concept, create a new job file for the exhaust.

INTERGRAPH

Turbo
Start the exhaust using nodes 1011 to 1020 for the first element.
From [1011
. .C Nome
To 1020
Continue on. After the reducer, there is a bend. Place a length of pipe 350mm long in the Z
direction, adding a bend to this pipe. Place a corresponding pipe 350mm long in the Y direction
afterwards to complete the bend.
Complete the rest of the exhaust.
Once finished, add one final element, inserted before 1011to 1020 and numbered 5 to 1010. Set
the pressure for this element to blank, and ensure that only this element has no pressure.
Connect via a CNode of 1010 at the anchor at node 1011.
The exhaust is now also complete. Notice that we have a node numbered 5 in both our inlet and
exhaust models. This node is a common location in both files. As such we can combine the models
and they will be linked at node 5 .
Error check the exhaust model, verify that the centre of gravity report gives similar weights to those
below:

Total Wght
N.
Pipe 7229.4
Insulation
Refractory
1065.4
0.0
Uf
Fluid 0.0
Pipe+ Ins+ Rfrty 8294.8 -3
Pipe +Fluid 7229.4 -3
Pipe + Ins+ Rfrty+ Fld 8294.8 -3

(
INTERGRA
*
PH
Turbo
Combine. Models
Save the Turbine exhaust as Turbo_Combined.c2
Select the Include Piping Files button to bring in the Inlet piping to create one single model .
UIUIIICIBI, <
Wt/ Sch: 71120

w
a 0 Seam W
0 W1 Factor:
.,
-Mill TolV : 12 5000
Include piping files
Include piping input files
Browse for the inlet model and click OK. (

IncludePipinq File?
'
File Name ReadNow? RotY Inc

Add
TURBO INLET N 0 0 1
Replace
Delete
Browse ..
The two models will be combined around node 5 - the common node in both files.
&

INTERGRAPH
*
Turbo
Select an element in the inlet. Notice that it can be selected, but the input screen has all fields
disabled.
Classic Piping Input

From: [ 50
_ . [UName
To : |GO |

OX | |
QY: | 300 C 0Q 0 mm |
This is because currently the inlet is simply being referenced and not fully included. Return back to
the combine pipe models screen. As well as the File name field, there are three other columns.
RotY - allows the included file to be rotated by a specified angle about the Y axis.
Inc - allows the node numbers in the new file to be incremented by a certain value, i.e. if the file
included was 10-20, 20-30 etc., we could increment by 1000 so that the nodes would become 1010-
1020, 1020-1030 etc.
The final column is Include Now ? This column allows users to choosing whether to reference or
.
actually permanently include the file This can be useful if checking that the file is correct before
including, so any changes required can be done in the original separate model.
If your model looks correct, change Include Now ? to Y.
File Name ReadNow? RolY Inc

TURBO INLET | | [o 0
Selecting an element in the inlet side of the piping will now show all the fields to be enabled.
>:
From 50
Name
To 60
~
>:
DX [ ]
DY 3000.000 mm
DZ
Offsets
Error Check and analyse the model, use the recommended load cases.
The analysis results should show that the expansion and Sustained stresses are acceptable. Check
the OPE case and note the loads on the nozzles at nodes 11 and 1011.

INTERGRA
*
PH
Turbo

FX FY F2 MX MY MZ
11 Rigid ANC
1(OPE) -427 -2894 489 -2698 365 133
/
90 Rigid +Y; Rigid GUI
1(OPE) 0 -3352 -197 0 0 0
100 Rigid ANC

1(OPE) 427 -5296 -292 166 519 -6474
1011 Rigid ANC
1(OPE) 905 -7288 -2021 1010 -736 -39B
l -J 1
There is a reasonable force on these nozzles, as the anchor points are supporting most of the weight
of the pipe. We will now take these forces and check them against NEMA SM23 to analyse the
turbine to see if the loads on the nozzles are acceptable.
NEMASM 23
The National Electrical Manufacturers Association (NEMA ) publishes and maintains a standard SM23
Steam Turbines for Mechanical Drive Service. This standard includes allowable loads that can be
applied safely to our turbine nozzles. CAESAR II incorporates this standard and a separate module
can be used to evaluate nozzles, using calculated loads from the piping analysis ( as we have just
done) .
sr
Return to the CAESAR II main window. Select the Analysis menu and select the NEMA SM 23 option
to load the module. You may need to use the to access the whole menu .
CM CAESAR II - [D:\TRAINING\CAESA
j File Input Output Toois Diagn
ID 0 i <k Statics
K Dynamics
SIFs <3> Intersections
SIFs <3> 8ends
WRC 107/ 297
Flanges
B 31 G .
Expansion Joint Rating
AISC
-
1 NEMA SM23
2 - API 610
3 - API 617
Steam Turbin 4 - API 661
5 - HEI Standard
-
6 API 560

IlNItKUKAPH
CADWorxs & Analysis Solutions
Turbo
Create a new file called passl.
If you wish, give the equipment a short description.
Select the NEMA Input Data tab.
The first data to enter is the direction of the equipment centreline. This must be specified as the
direction Cosines.
Z A.
i
The direction cosines are specified as the cosine of the angle of the centreline with the respective
axis. For example, if the centreline was as shown above, 60 from the Z axis and 30 from the Y axis,
the direction cosines would be:
Z = Cos 60 = 0.5
X = Cos 30 = 0.866
Our equipment centreline is along the Z axis, so the angle between the centreline and the Z axis is 0
and the angle between the centreline and the X axis is 90
Therefore the direction cosines are:
Z = Cos 0 = 1
X = Cos 90 = 0
Now we can define the nozzles. Click the Add Nozzle button
Description Nema Input Data

Equipment Centerline
Z-Axis Vertical [
Cos X: MOO [
Cos Z: TOM
Nozzles
| Add Nozzle | Forces / Moments acting on Nozzle

Nozzle: | |[Tj Ol [ o
Global Force FX

INTERGRAPH
Turbo
The Node number is the corresponding node number which matches the node number in the
CAESAR II model. Specify the Inlet first - so this node number is 11.
This is the Inlet nozzle and is 4 diameter
The next box is the Distance from Resolution Point to Nozzle. NEMA SM23 is ambiguous about the
point of resolution of the combined forces and moments. Select one of the three fields and hit FI to
bring up the help.
Enter the X distance from the Force/Moment resolution point to

the Nozzle.
NEMA SM 23 is ambiguous about the point of resolution of the combined
forces and moments. The resolution points have been interpreted to
be the following two points:
1. The face of the flange at the exhaust nozzle connection.
2. The intersection point of the exhaust nozzle centerline and the
equipment shaft centerline.
In order to resolve the forces and moments at the current nozzle

connection, enter the X distance from the current nozzle to each
connection. Distance from the exhaust to the exhaust nozzle is 0.0.
Phone:(+ 1)281-890-4566 E-mail : caesarii@intergraph.com

Fax:(+ 1)281-890-3301 Web: http://www.coade.com
This point is the distance from the resolution point (face of the exhaust nozzle flange) to the nozzle
at node 11. This is as follows:
DX = +100 -150 = -50 mm

DY = -300 + 500 = +200 mm
DZ = +450 + 50 = 500 mm
.
The basic nozzle information is input The final thing to do for this nozzle is to apply the loads on this
nozzle. We already have the loads in the CAESAR II job file that we have just analysed. So these
.
loads can be imported straight into NEMA SM 23 module Click the Select Loads Job and Load Case
button.

INTERGRAPH
*
Turbo
c
" NFMA 23
j File Edit View
- [D:\TRAINING\CAESAR II\TURBINE_ PASS1]
LDoy sqa $2 ta &

[Description Nema Input Data
Equipment Centerline
Z-Axis Vertical CosX ODM Cos Z 1 000
Nozzles
Add Nozzle Forces /Moments acting on Nozzle

Nozzle: 1 : of 1
Delete Nozzle Global Force FX
Node Number 11
Global Force FY:
Nozzle Type INLET
Global Force FZ
Nominal Diameter: 4 . ( 100 mm.)
in
Global Moment MX
Distance (rom ResolutionPoint to Nozzle
Global Moment MY
DX -50.000
Global Moment MZ
DY. 200.000
DZ 500.000 Select Loads Job and Load Case
Factor For Allowable Increase (optional)
Ready NUM
Browse to the combined turbine model and select the operating case.
it TiUyjfcSTWrat i 1
CASE 2 (SUS W+Pl

The loads will be imported from the job, these will be the loads at node 11 (as we specified the node
number as 11).

INTERGRAPH
*
Turbo
120
Nozzles

Nozzle I : oi i
Delete Nozzle Global Force FX -427 000
Node Number 11
Global Force FV -2894 000
Nozzle Type' INLET
Global Force FZ 489 000
Nominal Diameter 4 in. ( 100 mm.)
Global Moment MX -2698.000
Distance from Resolution Point to Nozzle
Global Moment MY 365.000
DX -50000
Global Moment MZ: 133.000
DV 200.000
Select Loads Job and Load Case
DZ 500000
'
Refresh Loads from Current Job

CASE 1 (OPE) W+T1*P1
D:\TRAINING\CAESAR ll\TRAINING\TUR
Previously Retrieved Loads
The inlet nozzle is now complete. Select to add a new nozzle and enter the Exhaust nozzle details.
As before, import the loads from the OPE case in the combined job file.
Nozzles
Forces /Moments acting on Nozzle
( Add Nozzle
| Palate Nozzle |
Nozzle
TEI 01 2
Global Force FX 905 000 Ns
Node Number 1011
Global Force FY -7288 000
Nozzle Type EXHAUST ] ]
T
-
Nominal Diameter 6 in. ( 150 mm.) ]
DX 0000
DY 0.000
Global Moment MX 1010 000
Global Moment MZ
-
Global Moment MY 736.000
-398.000
/v > /
DZ 0.000
Refresh Loads Irom Current Job
CASE 1 (OPE) W*T1 *P1
D:\TRAINING \CAESAR ll\ 270212\TURBO
Once complete, analyse the model using the Running Man icon.
I D O Q S . K Cl 0 fiE|
Description Nema Input [ Analyze
Another tab will now be present showing the results of the analysis. The analysis fails.

(
INTERGRAPH
*
Turbo
Overall Status **FAILED**
.
The Inlet and Exhaust both fail the analysis A closer look at the results shows that the FY is by far
the leading cause of the failure at >250% of the allowable.
Nozzle Loads & Summations Allowables % of ALLOW. Status

{ N. & N.m. ) (lb. & ft-lb)
SFX = -1532 -344 50* DC = 361 95.53

SFY = -10182 -2289 125* DC = 901 253.95 **FAILED**
SFZ = -478 -107 100* DC = 721 14.90
FC ( RSLT ) = 10308 2317
SMX = -35 -26 250* DC = 1803 1.43

SHY = -560 -413 125* DC = 901 45.83
SMZ = 143 106 125* DC = 901 11.72
MC(RSLT) = 579 427
2 FC + MC 5062 250* DC = 1803 280.78 **FAILED**
Save and Close the NEMA module and return to the piping input.
Looking at the input, it can be seen that the weight of the piping causing the FY will also clearly
result in the MZ moment being excessive - there is very little supporting the weight of the piping
.
other than the nozzles themselves The only other supports are on the headers.
( We need to support the weight of the pipe. Let us focus on the Exhaust first.
Let us support the weight of the pipe to reduce the FY component. Locate a Y support below the
elbow. This will be node 1039. We have not defined node 1039, only 1030 and 1040; so why 1039 ?
When building the model, it is built in the following way:
1030
"
71040
1050

INTERGRAPH
Turbo
Once a bend is inserted, CAESAR II moves node 1040 to the end of the bend, and inserts two
intermediate nodes:
1038
-
1030 T1039
1040
1050
These intermediate nodes are added by default at 0 around the bend, and at the mid-point of the
.
bend This can be seen in the Bend auxiliary data (single click on the bend check box on element
1030 - 1040). M is used to designate the mid-point of the bend.
039
Angle 1: M Nodel
' 038
Angle 2: 0.000
Angle 3:
Node 2
Node 3
'
These nodes can be moved to the required location if needed for any reason by simply editing the
angle. But we just wish to add a +Y support under the mid-point of the bend, at node 1039.
Add a +Y at 1039.
4
Auxiliary Data
Node: 1039 i CNode :
Type: |*Y H Gap:!

Stif: Mu: j

INTERGRAPH0
Turbo
Re-run the analysis.

Check the SUS and expansion stresses, these should again be OK. Now review the OPE case restraint
summary to check if the load on node 1011 has reduced.
.
The loads on node 1011 are the same. The loads on 1039 are 0 This restraint is not taking any load
in the OPE case.
NODE Load Case

FX FY FZ MX MY MZ
N. N. N. N.m. N.m. N.m .
1011 Rigid ANC

1(OPE) 905 7288 2021 1010
- 736 -398
1039 Rigid +Y
1(OPE) 0 0 0 0 0 0
View the 3 D plot to see the reason for this. View the deflected shape (you may need to increase the
deflection scale). From a left view, it can be seen that the expansion is causing the pipe to lift off the
support at node 1039 .
The Operating/Displacements report confirms this, node 1039 is experiencing 0.614mm

displacement upwards - lift off.
DX DY DZ RX RY RZ
NODE
mm . mm. mm. deg. deg. deg.
1039 -0.196 0.614

J 1.440 -0.0289 -0.0165 0.0013
The load on node 1011 has not changed. As such there is no need to run another NEMA analysis -
the results will be identical. Therefore, return to the input.

INTERGR
*
APH
Turbo
Change the design by replacing the Y restraint with a spring hanger.
Select a Carpenter and Paterson spring hanger, and enter -500 in the Available Space field. The can
will be shown as below.
1'
Auxiliary Data o x
4 Node: 1039
Design Data
Extended Range
Cnode:
.
Hanger Table: 16 - Carpenter 8 Pate
Cold Load Hot Load Centered
Available Space (neg for can): -500 000

Allowable Load Variation (%): 25.000
Re-run the error check and visit the Load cases window. We have added spring hanger into our
model, so we require the hanger cases to determine the hanger size. Use the recommended load
cases again and analyse .
Cas Load Cass Description
1 W(HGR) WEIGHT FOR HANGER LOADS
2 WT1 *P1(HGR) OPERATING FOR HANGER TRAV
3 WT1 P1 *H(OPE) OPERATING CASE CONDITION 1
A W*P1H(SUS) SUSTAINED CASE CONDITION 1
As before, the SUS and EXP cases are well within the code allowables. Check the restraint summary
for the OPE case.

INTERGRAPH
Turbo
r FZ MY MZ
NODE Load Case
FX Fi MX
N. N. N. N.m. N.m. N.m.
1011 Rigid ANC

3(OPE) 895 - 2440 - 1929 - 1114 - 684 - 356
1039 Prog Design VSH

3(OPE) 0 - 4867 0 0 0 0
The spring hanger is taking some load now (4800 N ) and the toad on the restraint at 1011 is much
reduced .
Return to the NEMA module and we will re -analyse with our new loads.
-
Save As... on the existing NEMA file, and select Nozzle 2 of 2 the exhaust. The Inlet has not
changed so there is no need to re-import the inlet loads.
Refresh the loads from the current job to import the new changed data.
Nozzles
Add Nozzle Forces/ Moments acting on Nozzle
Delete Nozzle
Nozzle
Node Number 1011

I Global Force FX. 895.000
Global Force FY -2440.000

Nozzle Type EXHAUST
-
Global Force FZ 1929.000
Nominal Diameter 8 in ( 200 mm .)
Global Moment MX 1114.000 -

Global Moment MY - G 84.000
DX 0.000
Global Moment MZ -358.000
DY 0 000 ,
- 4
IAT C Irth i
DZ 449.999
CASE 3 (OHfc) W+Tl + HT + H
D:\ TRAINING \ CAESAR ll \TURBO COMBII _
Once done, rerun the NEMA analysis. The exhaust still fails, but now only just (approx. 106% of the
allowable )
EXHAUST 1011 FX=

FY =
-1929
-2440 -
3F + M < 500 D(used)
FZ =
Fr=
- 895
3237
.
728
=
3F + M 3182
MX*
MY =
-356
-1114
684
F
-
500 D(used) =
% of ALLOW. *
3000
106.08
MZ =
Moments due to
Mr*
Force Resolution"
1355 M = 999
-- -FAILED
MX= 0
MY* 0
MZ -
0

INTERGRAPH 0
Turbo
126
The highest moment occurring at the exhaust nozzle is the MZ and this is caused by the FX force .
However as NEMA SM 23 defines its own axis convention, these are the local forces and moments,
not the CAESAR II global forces and moments. We need to figure out which forces and moments are
causing the issue in terms of the CAESAR II piping model axes rather than the local NEMA axes .
Recall the results:
FY FZ MX MY MZ
NODE Load Case N. N. N.m. N.m. N.m.
1011 Rigid ANC

3(OPE) 895 -1114 -684 -356
So the FX force of -1929N in NEMA is the global FZ force. The local MZ moment 1114Nm is the
-
global MX moment.
If we reduce these forces/moments in the piping input, this should further reduce the load on the
nozzle and bring us within the NEMA allowables.
The Inlet of course also still fails as we have not changed this.
Return to the CAESAR Output for this model, and view the deflected shape. If necessary, increase
the deflection scale to view the model.
pii Static Output Processor - [D:\TRAINING\C
\ File View Filters Reports Options PlotOptions Plot \
ago
' o j g D * Jl 5
K '
+ - gfl3D PloF
Load Cases Analyzed
|j Load Case: 3 (OPE) W+T1+P1+H -jl

ifJi <3> jjf Jl X - <* &
P

5
i
From a plan view it can be seen that the leg shown below is expanding in the Z direction. The
element running in the -X direction (highlighted yellow below ) is not flexible enough to absorb

INTERGRAPH
Turbo
enough of this expansion, which is ultimately the cause of the FZ force at the nozzle connection.
1
r
If we can add more flexibility in here then this leg can absorb some of the expansion and reduce the
Z force and X moment.
A simple way to make this change is to increase the length of the highlighted leg. In doing this, to
.
keep everything in the correct locations (i.e the supports on the header ), the header pipes must be
increased and decreased in length by the same distance as appropriate. Effectively this change is
really just relocating the tee.
A simple way to make this change is to use the graphics tool.
Return to the piping input and select a plan view
Select the Move Geometry function
Move Geometry
Select/ move nodes or

node groups.
This will highlight all the nodes with a circle. Select the nodes as shown below in the blue rectangle
to include the nodes that we wish to move
(
INTERGRAPH
*
Turbo
nr
IJ )
Now ensure that the move geometry is set to move along the X axis
Edit M<
pTn gy
Move Geometry ( X- Axis)
Mouse movement is
restricted to X axis.
<TAB > to change.
Single click inside one of the highlighted node circles. A dimension graphic will now be attached to
.
the cursor, which updates as you move the cursor along the X axis Notice the value changing as you
drag.
(

INTERGRAPH
CADWorx & Analysts Solutions
Turbo
3j(
.
MS 0.0
H
We wish to move the selected geometry 1000mm in the -X direction. You can drag the cursor until
the value in the box reads -1000, or more accurately it is better to type in the distance you wish to
move. Simply type in -1000 (remember the minus symbol) and hit enter.
The system should now update and the tee will relocate. To exit Move Geometry mode, simply
select another mode such as orbit/pan etc.
( r J
C
t
Rerun the analysis
The SUS and EXP cases will still be within the allowables. It is the OPE case that we care concerned
with. The loads on the Exhaust nozzle before the change were

INTERGRAPH0
Turbo
130
FX FY FZ MX MY MZ
1011 Rigid ANC

3(OPE) 095
-
2440 -1929 -1114 -684 -356
These loads will have now changed and the FZ and MX moments which were causing an issue
beforehand have now dropped:
NODE Load
T
Case
FX
N
FY
N. FZ MX
N.m. N.m.
MY MZ
N. m .
1011 Rigid ANC

3(OPE) 1024 -1299 -1124 - 879 -506 -478
Rerun these loads through the NEMA SM23 module.
Nozzles
Delete Nozzle
Nozzle E Global Force FX. 1024000
Node Number 1011
Nozzle Type EXHAUST
Global Force FZ -1124000
Nominal Diameter 6 in. ( 150 mm )
Global Moment MX 879.000 -
Global Moment MY -506000
DX 0 000
Global Moment MZ -478 000
DY 0 000
DZ 0 000
CASE 3 (OPE) W*Tl +P1+H
D:\ TRAINING\CAESAR II\TRAINING \TUR
The exhaust nozzle now passes

INTERGRAPH
0
Turbo
--1299
EXHAUST 1011 FX= 1124 3F + M < 500*0(used)
FY*
FZ*
Fr=
-2000
1024
F = 450
3F + M = 2176
500*D(used) = 3000
MX* -478
MY*
MZ=
-879
506 % of ALLOW. = 72.53
Mr* 1121 M = 627
Moments due to "Force Resolution"

MX* 0
MY= 0
MZ= 0
Moments About Resolution Point

(Algebraic addition of the moments above)
MX* -506
476 N.m .
MY*
MZ=
-679 N.m.
N.m.
The inlet nozzle of course still fails as we have not made any changes to this piping.
Now let us reduce the load on the inlet. To do this, break element 40-50 with a new node number
42. This node should be 300m from node 40.
Locate a spring hanger at node 42. As before, select Carpenter & Paterson. Re -run the analysis and
check the OPE restraint summary. The load on node 11 will be reduced.
NODE Load Case

FX FY FZ MX MY MZ
N. N. N. N.m. N.m. N.m.
11 Rigid ANC
3(OPE) -
471 923 479 242 462 123
42 Prog Design VSH

3(OPE) 0 -4333 0 0 0 0
Return to the NEMA module and Save As... this file. Re-import the loads for the inlet nozzle and re
run the NEMA analysis.
The Inlet should now also pass.
INLET ii FX* 479 3F + M < 500*D(used)

FY* 923
FZ* 471 3F + M = 1165
=
Fr*
MX*
MY*
1142
123
462
F 257
500*D(used)
% of ALLOW.
2000
58.26
MZ*
Mr*
-536
242
M* 395
Moments due to "Force Resolution"

MX* 48
=
MY -212
=
MZ 366
The whole turbine passes

INTERGRAPH

Turbo
132
Overall Status PASSED
The piping system is acceptable in within the code allowables, and the loads on the turbine are also
within the allowables of NEMA SM23.

INTERGRAPH
*
Manifold
133
Manifold
This exercise demonstrates multiple load cases can be used along with multiple operating conditions
in order to evaluate various what if scenarios. In addition, the API 610 module is used to evaluate
loads on pumps.
Other features shown include naming nodes and naming load cases to make reviewing the results
easier.
The model below will also be on the hand-out. Notice that the three branch legs are virtually
identical. The input should be setup to take advantage of this trait through the use of the element
duplication facility.
60
a
oj
\
>
>
.
> Y
55
&
s
3> A
2 X
Note the axial stop.

INTERGRAPH
0
Manifold
134
.
Begin at node 10 There is a 300# flange at the nozzle connection, followed by a length of pipe. The
overall length of these two elements is 375mm according to the isometric. Therefore the length of
the pipe needs to be 375mm minus the length of a 300# flange.
The easiest way to model in this situation is to model the whole 375 mm as pipe and then use the
valve/flange database to insert the flange at the start of the pipe for the first flange as follows:
To keep the node numbers consistent, change the nodes to read 10 to 30. Make this element
375mm long. This is 4 STD wall pipe, A 106 B material, water filled (1.0 SG) with 50mm Calcium
silicate insulation at 120C and 20 bar pressure.
From 10
To 30
J
OX.
DY: 375 000 mm
DZ:
G Offsets
Next, with element 10 to 30 highlighted, access the Valve/ Flange database
i
DZ
Offsets
[ Valve
V; Flange database
ME Access valve and flange

'database
mb
Select a 300# Flange, and specify that this should be placed at the From End of the element
FtigidType End Type Class
GATE SLG 150

GLOBE NOFLG 300
CHECK THREAD 000
CONTRL SOCKET 800
BALL 900
PLUG 1500
BTRFLV 2500
FLGPR
[FLANGE
O Whole element
B- m end
Flange Valve - Flange

O To end O Both ends
Activate Range Check
OK Cancel

INTERGRAPH
Manifold
This will be split into two elements now, and due to the node numbers we set (10-30) this has been
split to 10 to 20 and 20 to 30.
>>
From 10 From 20
Nome Nome
To To 30
20

DX DX
DY 68.900 mm DY 286.100 mm
DZ DZ
Offsets Offsets
Continue on and model all the way to the end anchor as shown.
Note the axial stop at node 80 as well as the +Y support.

Note that the bend has not yet been specified at node 70.
10
120
50
0
( 0
.
Use the duplicate feature to create the remaining two legs for Pumps B and C Increase the nodes
by 1000 each time .
You will not see the new elements initially, as they will be in the same location as run 10 to 70. Find
elements 1060-1070 and change to 1060-90. Also do the same for 2060-2070 and change to 2060-
100
The elements will all now be connected. Finish by specifying the bend at node 70.

INTERGRAPH

CAESAR M Statics Training
Manifold
136
120
050 040
030
040 US
030
0?B
(
0
Now that the model is complete, we can enter the loading information. The hangers are to be
designed with the entire system hot. Then, each branch line must in turn be run at ambient with the
remainder of the system hot. These four conditions can be evaluated in a single run, using four
different temperature and displacement vectors.
First we will label the pump locations so that we can easier review these locations in the results.
Select element 10-20 and double click the Name check box.

From 10
To 20 HT*
Specify that the from Node (node 10) is labelled as Pump A
Node Names
From: PumP H
To:
Repeat this for Pumps B and C
Next we wish to reduce the loads on the pumps by having the hanger support the riser weight. The
.
hanger algorithm works by distributing the weight evenly among all supports If we free the pump in
the Y direction at node 10, this will ensure that the weight is not distributed at this point - and so is
supported by the hanger. Do this by specifying the Hanger as follows:
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Node : 48
B Design Data
Cnode
Hanger Table 16 - Carpenter & Pate)

Extended Range QCold Load Hot Load Centered
Available Space (neg . for can)
g
Allowable Load Variation (%) 25.000

Max Allowed Travel Limit
No Hangers at Location:
Allow Short Range Springs 0
Operating Load (Total at Loc.):
Hanger Hardware Weight:
Multiple Load Case Design Option:

Free Restraint at Node 10
Free Restraint at Node
Free Code 1 - Y
Repeat this for Pumps B and C .
Now we need to specify the loading conditions, as mentioned before, we wish to evaluate the
system in four conditions. We can do this by specifying four different temperature/pressure cases,
and four different displacement vectors at the pumps.
All pumps on T1 PI D1
Pump A idle T2 P2 D2
Pump B idle T3 P3 D3
Pump C idle T4 P4 D4
Enter the temperatures as follows. The element listing displays the value in red whenever it changes
from the previous value.
(
'
S
V

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138
FROM TO T1 T2 T T4
NODE NODE Deg C Deg C Deg C Deg C
1 10 20 22.0000 120 0000
2 20 30 120.0000 22 0000 120 0000 120.0000
3 30 40 120 0000 22.0000 120 0000 120 0000
4 40 50 120.0000 50.0000 120 0000 120 0000
5 50 60 120.0000 75 0000 120 0000 120 0000
6 60 70 120.0000 75 0000 120 0000 120.0000
7 70 80 120 0000 100.0000 120 0000 120.0000
8 80 90 120.0000 120.0000 120 0000 120.0000
9 90 100 120.0000 120 0000 120 0000 120.0000
10 100 110 120.0000 120 0000 120.0000 120.0000
11 110 120 120.0000 120 0000 120.0000 120.0000
12 120 130 120.0000 120.0000 120.0000 120.0000
13 130 140 120.0000 120 0000 120.0000 120.0000
14 1010 1020 120.0000 120 0000 22.0000 120.0000
15 1020 1030 120.0000 120.0000 22 0000 120.0000
16 1030 1040 120.0000 120 0000 22.0000 120.0000
17 1040 1050 120.0000 120 0000 50.0000 120 0000
18 1050 1060 120.0000 120.0000 75.0000 120 0000
19 1060 90 120.0000 120.0000 100.0000 120 0000
20 2010 2020 120.0000 120.0000 120.0000 22 0000
21 2020 2030 120.0000 120.0000 120 0000 22 0000
22 2030 2040 120.0000 120.0000 120.0000 22 0000
23 2040 2050 120.0000 120.0000 120.0000 50 0000
24 2050 2060 120.0000 120.0000 120.0000 75 0000
25 2060 100 120.0000 120.0000 120.0000 100 0000
.
Use the graphics to verify that the temperatures are correct Note that the temperatures do not
simply stop being 120C and suddenly drop to ambient. The way we have entered the temperatures
give a basic approximation of a temperature gradient.
i liiir. - A k oe ; jjit
ioJo io to
rilwrk
1
Temperature 1
J No
Highlight Temperature 1

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139
T1 All same temperature T2 - Pump A idle
( i
T3 - Pump Bidle -
T4 Pump C idle
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140
Perform a similar task with the pressure. Only this time the pressure will drop from 20 bars to 0
after the valve. It is at fill pressure right up to the valve, then it will drop.
Enter the pressures as shown below:
FROM TO P1 P2 P3 P4
NODE NODE bars bars bars bars
1 10 20 20 0000 0 000 20.0( 20.0000
2 20 30 20.0000 0.0000 20.0000 20,0000
3 30 40 20.0000 0 00 20 0000 20.0000
4 40 50 20.0000 20 00 20.0000 20.0000
5 50 60 20.0000 20.0000 20.0000 20.0000
6 60 70 20.0000 20.0000 20 0000 20.0000
7 70 80 20.0000 20.0000 20.0000 20.0000
8 80 90 20.0000 20.0000 20.0000 20.0000
9 90 100 20.0000 20.0000 20.0000 20.0000
10 100 110 20.0000 20.0000 20.0000 20.0000
11 110 120 20.0000 20.0000 20.0000 20.0000
12 120 130 20.0000 20.0000 20 0000 20 0000
13 130 140 20.0000 20.0000 20.0000 20.0000
14 1010 1020 20.0000 20.0000 0.0000 20.0000
15 1020 1030 20.0000 20.0000 0.0000 20.0000
16 1030 1040 20.0000 20.0000 0.0000 20.0000
17 1040 1050 20.0000 20.0000 20.0000 20.0000
18 1050 1060 20.0000 20.0000 20.0000 20.0000
19 1060 90 20.0000 20.0000 20 0000 20.0000
20 2010 2020 20 0000 20.0000 20 0000 0.0000
21 2020 2030 20.0000 20.0000 20.0000 0.0000
22 2030 2040 20.0000 20.0000 20.0000 0 0000
'
23 2040 2050 20.0000 20.0000 20.0000 20.0000

24 2050 2060 20.0000 20.0000 20.0000 20.0000
25 2060 100 20.0000 20.0000 20.0000 20.0000
(\

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141
Again the graphics can be used to verify the correct pressure has been specified
PI - All same pressure P2 - Pump A idle
4
P3 - Pump B idle P4 - Pump C idle

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142
Finally we need to specify the pump nozzle displacement. The pump discharge nozzle vertical
growth is 0.75mm, when the pump is running. Therefore we also need 4 displacements at each
pump. Enter the displacements as in the table below. An example for Pump A is shown in the
screenshot afterwards.
Pump A Pump B Pump C

D1 0.75 0.75 0.75
D2 0 0.75 0.75
D3 0.75 0 0.75
D4 0.75 0.75 0
Node 1 10
Vector 1 Vector 2 Vector 3 Vector 4

DX 0 0000 0 0000 0 0000 0 0000
OY 0 7500 0 0000 0 7500 0 7500
DZ 0 0000 0 0000 0 0000 0 0000
RX 0 0000 0 0000 0 0000 0 0000
RY 0 0000 0 0000 0 0000 0 0000
RZ 0 0000 0 0000 0 0000 0 0000
' ']
The model is now complete. Run the error checker. You should receive 3 notes - two on the hanger
design, plus the C of G report which should give a weight similar to:

Total Wght
N.
Pipe : 6328.8
Insulation : 1054.5
Refractory : 0.0
Fluid : 1717.4
Pipe + Ins+ Rfrty : 7383.3
Pipe+Fluid : 8046.2
Pipe + Ins+ Rfrty+Fld : 9100.8
Correct any errors or warnings you may receive.
.
Access the Static Load cases We require a number of load cases now - one each for SUS, OPE and
EXP for each of our situations, i.e. 12 cases. Plus we require the hanger design cases. The hangers
should be designed for the system when all pumps are hot.
The recommended cases should satisfy these requirements.

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143
Load Cases Stress Type |

L1 w HGR
L2 W+D1+T1+P1 HGR
L3 W+D1+T1+P1+H OPE
L4 W+D2+T2+P2+H OPE
L5 W+D3+T3+P3+H OPE
L6 W+D4+T4+P4+H OPE
L7 W+P1+H SUS
L8 W+P2+H SUS
L9 W+P3+H SUS
L10 W+P4+H SUS
L11 L3-L7 EXP
L12 L4 -L7 EXP
L13 L5-L7 EXP
L14 L6-L7 EXP
As we have a number of load cases now, it is becoming a little confusing to work out each time
which combination of loads is which case. To make this easier, we will rename the load cases.
Access the Load Case Options tab and rename the load cases to reflect the situation.
Load Case Name
L1 WEIGHT FOR HANGER LOADS

L2 OPERATING FOR HANGER TRAVEL
L3 OPERATING CASE ALL PUMPS ON
L4 OPERATING CASE PUMP A IDLE
L5 OPERATING CASE PUMP B IDLE
L6 OPERATING CASE PUMP C IDLE
L7 SUSTAINED CASE ALL PUMPS ON
L8 SUSTAINED CASE PUMP A IDLE
L9 SUSTAINED CASE PUMP B IDLE
L10 SUSTAINED CASE PUMP C IDLE
L11 EXPANSION CASE ALL PUMPS ON
L12 EXPANSION CASE PUMP A IDLE
L13 EXPANSION CASE PUMP B IDLE
L14 EXPANSION CASE PUMP C IDLE
Run the analysis
The list of load cases will still be the CAESAR II Load Case name. To change this, go to Options > Load
Case Name and select User Defined Loadcase Name instead
O CAESAR II Loadcase Name

@ User Defined Loadcase Name
OK Cancel
In addition, to make it easier to identify the pumps, choose to display the Node Name in the reports
as well as the number . Again, this is accessible via Options menu > Node Name

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PflniWnrv &
CADWorx 9. flnilitelp Cnlufinni
Analysis Solutions'
Node Number Only O Node Name Only
Number (Name) Name (Number)
Number - Name Name - Number
Cancel
Verify that the system is within the allowables for B31.3 in all situations, both EXP and SUS.
Also check the OPE loads on the pump nozzle connection.
API 610 Analysis

The model is complete and satisfies the requirements of B31.3. We can now evaluate the pump
nozzles to ensure that the nozzle connections satisfy the requirements of API 610 for the pump.
A total of 12 API-610 evaluations must be made in order to find the worst case scenario. These
scenarios are shown below:
Pump A - All pumps on Pump A - Pump A idle Pump A - Pump B idle Pump A - Pump C idle
Pump B - All pumps on Pump B - Pump A idle Pump B - Pump B idle Pump B - Pump C idle
Pump C - All pumps on Pump C - Pump A idle Pump C - Pump B idle Pump C - Pump C idle
Access the API-610 module from the CAESAR II main window and create a new file for the first
iteration - Pump A with all pumps activated.

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AR OJliB
ip&y e g ss i p s
Description input Data 1 Suction Nozzle Discharge Nozzle
Equipment Description
PUMP A - ALL PUMPS ACTIVE
Ready CAP NUM
.
Move to the Input Data tab to specify the data for the pump Note the API coordinate system is
different from the CAESAR II coordinate system, and varies depending on the orientation of the
pump in question. CAESAR II handles this transposition automatically. We are also only concerned
with the Discharge nozzle; as such we do not need to enter any data into the Suction Nozzle tab or
fields.
We wish to evaluate the discharge nozzle. This is pump A, so the nozzle is node 10. Fill in the
correct data for Node 10.

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46
Input Data Suction Nozzle Discharge Nozzle
Vertical In-line Pump
Centerline Direction Cosine X 1 D00

Z-Axis Vertical]
Centerline Direction Cosine Z 0 000
Base Point Node Number 4000
Suction Nozzle Node Number
Suction Nozzle Type
Suction Nozzle Nominal Diameter
(
Discharge Nozzle Node Number 10
Discharge Nozzle Type Top
Discharge Nozzle Nominal Diameter 4 in ( 100 mm.)
FadortorTable 4 Allowables 2000
Now we need to specify the loads on the discharge nozzle. As before, these loads can be imported
from the analysis just done.
Select Load Case 3 - Operating case for all pumps active .
fGASE.3 fOBE) WTOI+TI+PI HI

CASE 4 (OPE) W+D2+T 2+PZ+H
CASE 5 (OPE) W+D3+T3+P3 +H
CASE 6 (OPE) W+D4+T4+P4+H
CASE 7 (SUS) W+Pl+H
CASE 8 (SUS) W+P2+H
CASE 9 (SUS) W+P3+H
Also, for the analysis, we will assume that the distance from the centreline to the nozzle is zero.

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147
it Data Suction Nozzle Discharge Nozzle
Nozzle Location (From Pump Center)
DX 0.000
DY 0.000
DZ 0 000
Forces on Nozzle
Global Force FX -92.000
.
Moments on Nozzle
Global Moment MX 291.000
Global Moment MY: 58.000
Global Moment MZ 634.000
Select Loads Job and Load Case | 0 \ TRAINING \ CAESAR ll \ TFtAINING \MAN
CASE 3 (OPE) W*D1 *T1 *P1+H
All the data has been input, so the analysis can now be run.
jp [u:\TRAINING \
-
File Edit View
iDBH eg 06 &igB
Description
D( [ input Data [ S| Analyze }ioz;

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148
Description | Input Data j Suction Nozzle | Discharge Nozzle | Errors/Warnings Equipment Report
z distance
- 0.0 mm.
x force = -92.0 N. 1423 0.06 Passed

y force = -115.0 N. 1156 0.10 Passed
z force = -313.0 N. 1779 0.18 Passed
x moment = 291.0 N.m. 1329 0.22 Passed

y moment
z moment
=
-
-634.0 N.m.
58.0 N.m. 1003
678 0.94
0.06
Passed
Passed
Check of Condition F.1.2.b Requirement Status
(FRSa/1.5FRSt4) + (MRSa/l.5MRSt4) 0.000 < or 2.00 =

Passed =
|
(FRDa/1.5FRDt4) + (MRDa/1 II o 350 < or 2.00 Passed =
Check of Condition F.1.2.c Requirement Status
1.5 ( FRSt4 + FRDt4 ) = 3803. >

1356. >
346. (FRCa) Passed
634. (MYCa) Passed
2.0 ( MYSt4 + MYDt4 )
1.5 ( MRSt4 + KRDt4 ) = 2705. > 700. (MRCa) Passed
Overall Pump Status ** PASSED --

The results show that Pump A is OK for this condition. However, to determine the worst case, we
must perform the other eleven evaluations.
Repeat the above task for all the remaining pumps.

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149
After completing all twelve iterations, you should notice that one of the iterations fails. This is Pump
C with Leg B Idle .
y distance 0.0 mm.
2 distance = 0.0 mm -
X force 1243.0 N. 1423 0.67 Passed

V force s 156.0 N. 1156 0.14 Passed
z force = -
1194.0 N. 1779 0.67 Passed
X moment
y moment
s
=
-1760.0
316.0 N.m.
N.m.
1329
676
0.24
2.60
Passed
Failed
z moment s
-272.0 N.m. 1003 0.27 Passed
Check of Condition F.1.2.b Requirement Status
{FRSa/1.5FRSt4) + (MRSa/1.5MRSt4) 0.000 < or = 2.00 Passed

(FRDa/i.5FRDt4) + (MRDa/1.5MRDt4) 1.124 < or = 2.00 Passed
Check of Condition F.1.2.C Requirement Status
1.5 ( FRSt4 + FRDt4 ) s 3603. > 1731. (FRCa) Passed

2.0 ( MYSt4 + MYDt4 ) = 1356. > 1760. (MYCa) Failed
1.5 ( MRSt4 + MRDt4 ) = 2705. > 1809. (!
-
I RCa) Passed
Overall Pump Status ** FAILED **
From these results, it can be seen that the local Y moment is failing, and is 260% of the allowable. As
mentioned previously, the API -610 coordinate system is different to the CAESAR II local coordinate
system. In this case the local MY translates to the MZ in CAESAR II.
Return to the piping static output and review the results. View the restraint summary for all the
Operating cases .
Various Load Cases
NODE Load Case FX FY FZ MX MY M2

N. N. N. N.m. N.m. N.m.
10 ( PUMP A) Displ. Reaction

3(OPE) -92 -187
313 115 291 58 634
4(OPE) -326 -26 41 10 727
5(OPE) 149 -471 180 391 79 162
6(OPE) -70 -471
344 147 354 56 589
MAX -326/L4
- /L5 180/L5 391/LS 79/L5 727/L4
1010 (PUMP B) Displ. Reaction

3(OPE)
4(OPE)
79
312
--
390
563
-
-107
21
-17318-
9
--
110
111
273
-826
161
5(OPE) -350
442 364 -1439 -106 -92
6(OPE) -619 -111/L4
111 -826
183
2010 (PUMP C)
MAX
-442/L5
Displ. Reaction
-619/L6 - /L4
107 -173/L4 - /L5
-962 -9489 -186 -272

---
3(OPE) 982 1322
4(OPE)
5(OPE)
1003
1243
---
997
1194 -115
158- --318
225 -272
--
240 1376
1760
6(OPE)
MAX
407
1243/L5
-
130
1194/L5
-- 150/L5 --318 L5
225
/ -
202
282/L6 --
687
1760/L5
The MZ for Pump C in case 5 is the highest of any MZ moments - confirming the findings of the API
610 analysis.
View the 3D plot and view the deflected shape for Operating case with Pump B idle.

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150
The datum for the thermal expansion is the line stop at node 80. The expansion at the leg for pump
C is the greatest, and so is causing the higher moment at this point. Similar to the exercise SUPT01,
if we can adjust the datum for thermal expansion, we should be able to reduce the amount of
expansion which is causing the moment on Pump C.
This can be done by moving the line stop from node 80 to node 110.
Remove the Z restraint at node 80 and add a new Z restraint at node 110, then re-run the analysis.
Notice now that the restraint summary shows that Pump C has a much lower MZ now. The loads
have been more evenly distributed ( Pumps A and B have slightly greater loads, but these pumps
were OK anyway).
Pump C (2010) Displ. Reaction

5(OPE) 1147 -
772 466 753 225 - BB2
Return to the API 610 module and open the file which failed previously -
Select the Discharge nozzle tab. The loads on this pump have changed, so we will have to import
these new loads.
Use the Refresh Loads from Current Job button to bring in the new loads and re-run the analysis.

(
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Manifold
DX 0.000
DY 0.000
DZ 0.000
Forces on Nozzle
Global Force FX. 889.000
Moments on Nozzle
Global Moment MX 570 000

( Global Moment MY: 38 000
Global Moment MZ: -1129 000
Select Loads Job and Load Case D: \TRAINING \ CAESAR ll\TRAINING \ MAN
CASE 5 (OPE) W*D3+T3*P3H
This time the pump should pass - as we have reduced the loads sufficiently
y distance = 0.0 mm.

z distance = 0.0 mm.
x force = 889.0 N. 1423 0.62 Passed

y force
z force
=
=
--996.0
263.0 N.
N.
1156
1779
0.23
0.56
Passed
Passed
x moment 570.0 N.m. 1329 0.43 Passed

y moment = 1129.0 N.m. 678 1.67 Passed
z moment = 38.0 N.m. 1003 0.04 Passed
Check of Condition F.i.2.b Requirement Status

(
(FRSa/1.5FRSt4) + (MRSa/ l.5MRSt4) = 0.000 < or = 2.00 Passed
(FRDa/1.5FRDt4) + (MRDa/I.5MRDt4) = 0.826 < or = 2.00 Passed
Check of Condition F.1.2.C Requirement Status
1.5 ( FRSt4 + FRDt4 ) 3803. > 1361. (FRCa) Passed

2.0 ( MYSt4 + MYDt4 ) 1356. > 1129. (MYCa) Passed
1.5 ( MRSt4 + MRDt4 ) 2705. > 1265. (24RCa) Passed
Overall Pump Status ** PASSED **

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0
Tutor
Tutor
This exercise will develop various sequences of run - evaluate - modify workflow to determine the
acceptability of the system. Each of the evaluations of the system will develop another aspect of
CAESAR II.
Once the system is acceptable, we will generate a custom report and stress isometrics.
LDNG WELD
NECK
System parameters
Pipe: 8 diameter, standard wall, ASTM A-53 Gr B .
2" diameter, standard wall, ATSM A-53 Gr. B
Analysis temperature: 315C
Analysis pressure: 2 bar
Corrosion allowance: 0.8 mm
Insulation: 75 mm CaSi
Fluid: 0.8 SG
Pipe Specification: 150 pound class components
Design Code: B31.3
Valves: 8 Main Line - 150 # Flanged Check Valve

2" Bypass - 150# Flanged Gate Valve
Use Unreinforced Tee types

1
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Tutor
Node 10 is connected to a Pump and node 110 is connected to a vessel Nozzle. Their details are as
follows:
Pump Details:
10 inch end suction, 8 inch top discharge
Suction is -380 mm in X from pump centre
Discharge is 500 mm above and 300 mm in Z from pump centre
Piping load on suction nozzle given as: (4450,-3550,-5340) N and
(-4070,-3390,2170) N-m
Nozzle Details:
Fixed end is preceded by a long weld neck flange in the -Z direction:
00=247.65, wt = 22.225, length= 300 mm, weight=458 N
and a standard, 8 inch weld neck flange and gasket
r Model the system as shown in the isometric. When modelling the bypass loop, the Close Loop
command can be used if required to connect node 150 to 60. Change the node numbers to 150 and
60 and click the close loop button. CAESAR II will add in an element of the required length
automatically.
i
DX I
Piping loop dosed, length of element is: 450.000
nv -I J
Close Loop
]
Create an element with
existing node numbers to OK
close the loop
1
The completed model will look as the one below.

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154
Boundary Conditions
We now need to specify the boundary conditions for the analysis. The piping is connected to a pump
and a vessel at the termination points, so we can apply the effects of these to the relevant nodes.
Pump Connection - Node 10
The discharge is 500mm above (Y ) and 300mm in Z from pump centre
We have two options for the approach here.
1 . Calculate the thermal growth of discharge nozzle from pump base point.
Alpha= 0.003832 mm/mm
Displacements therefore:
X=0
Y = 500 x 0.003832 = 1.916 mm
Z = 300 x 0.003832 = 1.1496 mm
No rotational displacements
2. Add a construction element between the nozzle node (10) and the pump base with
appropriate material and temperature.
For this exercise, specify the displacement set for node 10 as above.
Bend Reducer
El Rigid .
SIFs 8 Tees [ Node 1 10
Expansion Joint
Vector 1 V jctor 2 Vector 31 Vector
Restraints [ J Displacements j DX 0 0000
Hangers Range Checks DY 1 9160
Nozzle Rex Nozzle Lml Check DZ 1 1496
Forces /Moments
RX
RY
0 0000
0 0000
r
Uniform Loads RZ 0 0000
Wind / Wave ! 0
Vessel Connection - Node 110
As before we have the same two approaches; provide the thermal growth of the nozzle, or model
the vessel. The thermal growth of the vessel is
X=0
Y = 8.43 Node 1 110
Z = -2.87
RX = 0
Vector 11 Vector 2 Vector
DX 0 0000 [
RY = 0 DY 8 4300
RZ = 0 OZ -2 8700
RX 0 0000
RY 0 0000
RZ 0 0000

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155
Support Riser
We wish to unload the pump discharge nozzle as much as possible, and also support the thermal
growth of the riser. To do this we will locate a spring hanger near the elbow (node 70).
Place a Carpenter & Paterson hanger at node 70

>
Node 70 Cnode.
Design Data
Hanger Table 16 - Carpenter & Patej J
Available Space (neg for can)
Allowable Load Variation (/i ) 25.000
( Support Horizontal Runs

The suggested maximum support spacing for 8 water filled pipe is 5.8m for horizontal straight runs.
75% of that spacing for horizontal spans including changes in direction would therefore be 4.35m.
This will support the pipe weight and so account for the SUS case. Since we will check these
Sustained stresses (and since the fluid weight is less than water-filled) we can exceed the suggested
spacing.
Locate a restraint on each horizontal 8 run using the Break function.
70-80 add node 75, located 1200mm before node 80

80-90 add node 85, located 3000mm after node 80
Add the following restraints:

Node 75
lx (double acting) Y restraint, with a friction coefficient of 0.3
lx guide with a gap of 8mm, again with friction
Node 75 CNode
Type y_ l ] Gap:[
Stif Mu 0.300
Node 75 CNode
Type Guide - Gap
Slil Mu 0.300
Node 85
lx (double acting) Y restraint, with a friction coefficient of 0.3
Node: 85 CNode
Type Y Gap
Stif Mu 0.300
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156
The model is now complete. Error Check the model and run the Recommended load cases.
Immediately it can be seen that there is an issue with the EXP case. Check the stresses for both the
EXP and SUS cases.
The SUS case is OK
Piping Code: B31.3 = -

B31.3 2008, December 31, 2008
CODE STRESS CHECK PASSED : LOADCASE 4 (SUS) W+Pl+H
Highest Stresses: (N./sq.nun. )

Code Stress: 17.2 Allowable: 119.4
The EXP case however is an issue:
Piping Code: B31.3 = B31.3 -2008, December 31, 2008
CODE STRESS CHECK FAILED : LOADCASE 5 (EXP) L5=L3-L4
Highest Stresses: (N./sq.mm. )

The only issue is at node 30, where the stress is 130% of the allowable.
Bending Torsion Allowable Ratio
Stress Stress
SIF In SIF Out Code Stress Stress Piping Code
NODE Plane Plane N./sq.mm. %
N./sq . mm. N./sq.mm. N./sq.mm.
30 415.19 -10.10 3.961 4.949 415.68 319.84 129.96 331.3
30 414.31 10.08 3.961 4.949 414.81 320.97 129.23 B31.3

40 79.85 -10.00 1.000 1.000 82.35 321.01 25.65 B31.3
Node 30 is the Tee connecting the bypass.
One of the easiest fixes for an overstressed component is to replace it with a stronger component.
Component strength is indicated by the stress intensification factor (SIF). Here, the stub-in branches
are overstressed. Their in-plane SIF is 3.96 and their out-plane SIF is 4.95. Adding a pad to these
tees will strengthen them. Check the effect of adding a pad by using the Tee SIF Scratchpad. Change
the unreinforced tee to a reinforced tee with a 9 mm pad. Using the Recalculate button will show
that the SIFs have been reduced to 2.04 and 2.38 for in-plane and out-plane respectively.

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Tutor
Node 30
-
Type 1 Reinforced
PadThk. 3 000 Header SIF(i) 2 037

Ftg Ro Header SIF(o) 2.383
Crotch R Branch SIF(i) 2.037
Weld ID Branch SIF(o) 2 383
Weld(d)
Fillet
Header OD 219 075

HeaderThk 8179
c Branch OD
Branch Thk. 3.912
60.325 flexibility Characteristic 0 232
Branch Section Modulus 19919.828
Recalculate Cancel
Accept these changes and apply to node 30.
Re- run the analysis and review the results.
The expansion case is now ~75% rather than 130%.
CODE STRESS CHECK PASSED : LOADCASE 5 ( EXP ) L 5= L 3-L 4
Highest Stresses : ( N . / sq . mm . > LOADCASE 5 ( EXP ) L 5=L 3-L 4

CodeStress Ratio ( % ) : 75.6 @ Node 80
Code Stress : 241.0 Allowable : 318.6
The SUS case is still 14%.
Hanger Sizing
Review the Hanger table with text. A Carpenter & Paterson DV 70 spring is selected .
THEORETICAL ACTUAL
NO . FIG . VERTICAL HOT INSTALLED INSTALLED SPRING HORIZONTAL
NODE REQD NO . SIZE MOVEMENT LOAD LOAD LOAD RATE MOVEMENT
1 1 1 1 ( mm . ) h ( N. ) l (N . ) 1 (N . ) . / mm . )
( KN ( mm ). -
70 1 DV70 5 17.142 1355 . 1544 . 0. 0. 19.686
CARPNTRS PATRSON LOAD VARIATION = 14 %
Hot Load 1355 N , deflection 17 mmm cold load 1544 N . We need to now see if this is appropriate.
View the Restraint summary for the OPErating and installed (SUS) cases.

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FX FY
NODE Load Case
N. N.
10 Displ. Reaction
3(OPE) 7171 -10518
4(SUS) 17 -5086
MAX 7171/L3 -10518/L3
Look at the operating load and installed load on the pump discharge nozzle (node 10). Typically,
with a spring hanger above the pump, the pump will see a positive (up) load in the cold state and a
negative (down) load in the hot state. Here, the piping pushes down on the pump in both states.
This spring is undersized. Why ? The calculated load carried by the spring is based on the overall
distribution of weight between all vertical supports. The interaction of the pump nozzle (anchor),
the spring and the other Y supports has very little load assigned to the hanger location. More
weight is carried by the pump rather than the spring hanger.
Deadweight that is resting on the pump must now be transferred to the hanger. The easy way to do
this is to remove the load-carrying capability of the pump in the initial weight analysis when the
hanger load is first calculated. To do this, CAESAR II allows the restraint to be freed - effectively
removing this node from the hanger sizing calculation, so the load is distributed amongst the
remaining support locations.
Return to the input and on the hanger; free the restraint at node 10 in the Y axis:
Node 70 Cnode
Design Data
jl 6 - Carpenter
Hanger Table
* Pate
Available Space (neg lor can)

Allowable Load Variation (t4) 25 000
Rigid Support Displacement Criteria '
Max. Allowed Travel Limit

No. Hangers at Location
Allow Short Range Springs a
Operating Load (Total at Loc )
Hanger Hardware Weight:
Multiple Load Case Design Option: h

Free Restraint at Noc s 10'
Free Restraint at Noc a:
Free Code. 1 - Y H
Now reanalyse the system.
Review the results again.

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The Expansion stress results are unaffected by this hanger change. The maximum SUS stress ratio is
also still around 14%.
Review the hanger table with text.
NO. FIG. VERTICAL HOT INSTALLED INSTALLED SPRING HORIZONTAL

70
+ +
1 DV70
+
11 17.220 7037. 8062. 0.
-
+ (mm.) + (N. ) + (N. ) + (N. ) (KN./mm.) (mm.)-
0. 19.690
CARPNTRSPATRSON LOAD VARIATION = 15%
A Carpenter & Paterson DV70 has been selected again, but the hot load has increased to 7000N and
the installed load has increased to 8000N.
.
C Review the restraint summary report to view the pump load ( node 10)
_ _
Load. Case
FX FY
NODE
N. N.
3(OPE) 6938 -5228

4(SUS) -270 984
The resized spring now pulls up on the pump in the cold position and unloads as the system heats
up. (The riser growth drops the load supplied by the spring.) This spring is much better than in the
first iteration; however it could be improved even more. The hanger data input provides for the
specification of the hanger operating (hot) load:
Node: 70 Cnode:
Design Data
HangerTable: [
l , , ,
Ca Pen er & Pa
ID Extended Range Cold Load Hot Load Centered
Available Space (neg lor can)
C .
Allowable Load Variation ( ' ) 25.000

Max. Allowed Travel Limit
No Hangers at Location
.
AllewiOhertRange Gpringa ig. WxVto Q /t <x Hfijr -
[[ Operating Load (Total atLoc ):

Op
Hanger Hardware WeigHt

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Pump Load
Review the restraint summary report for the OPE and SUS (installed) cases. The loads shown for the
.
pump are a little high in some directions - MX is almost 30000N However no indication is given that
these loads are excessive.
FY FZ MX MY MZ
NODE Load case N. N. N.ra. N.ra. N.ra .
10 Displ. Reaction
3(OPE) 6938 -5228 8237 29B25 -55670 -17220
4(SUS)
MAX
-270
693 B/L3
984
-5228/L3
-0
8237/L3
-
0
29B25/L3
-
-5567/L3 -
500
17228/L3
American Petroleum Institute Standard 610 (API 610) sets maximum nozzle loads for pedestal
supported pumps. CAESAR II provides this calculation. Run this analysis with the pump data
provided above and using the discharge loads from this analysis. Since both suction and discharge
nozzles are evaluated together, the Table 4 limits in API 610 can be doubled (see API 610 Annex F ).
API 610 Analysis

Access the API 610 module from the Analysis menu on the main window.
ID 0 i& Statics
" |8 Dynamics
WRC 107/ 297
Flanges
1 - NEMA SM23
2 - API 610 K
6 - API 560
W
Create a new file and input the pump data.
The pump centreline can be seen to be in along the X axis, therefore the angle between X axis and
.
pump Centreline is 0. The angle between the Z axis and the pump centreline is 90 The direction
cosines are therefore
X Cosine = cos 0 = 1
Z Cosine = cos 90 = 0
The Base point node number can be any arbitrary node number. This node number does not have to
appear in any of the piping model, but is used by API 610 as a point of reference about which to sum
moments.
The suction Nozzle is not defined in the piping model as we are given the loads so can input these.
We also know that this is a 10 End type suction nozzle.
The discharge nozzle is in our piping model, and is node 10. This is an 8 Top type suction nozzle.
As mentioned, since both suction and discharge nozzles are evaluated together, the Table 4 limits in
API 610 can be doubled.

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Vertical In-line Pump
Centerline Direction Cosine X: 1.000

Z-Axis Vertical
Centerline Direction Cosine Z 0 000
5 V > '
t v O &u M/
Base Point Node Number 1000 '
Suction Nozzle Node Number
Suction Nozzle Type End
Suction Nozzle Nominal Diameter 10 in. ( 250 mm.)

> IS
Discharge Nozzle Node Number 10
Discharge Nozzle Type; Tap

(
Discharge Nozzle Nominal Diameter 8 in. ( 200 mm.)
FactorforTable 4 Allowables 2 000
The suction nozzle loads and location have already been given:
Suction is -380 mm in X from pump centre .

Piping load on suction nozzle given as: ( 4450,-3550,-5340 ) N and ( - 4070,-3390,2170) N-m
t Data Suction Nozzle Discharge Nozzle | Equipmen
DX -380.000
DY. 0 000
DZ 0.000
( Forces on Nozzle
5 15 3
Global Force FX. 4450.000
Global Force FY -3550000
Global Force FZ -5340.000
Moments on Nozzle
Global Moment MX. -4070.000
Global Moment MY -3390.000
Global Moment MZ 2170.000
Select Loads Job andLoad Case

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The pump discharge nozzle is located 500 mm above ( Y) and 300 mm in Z from pump centre.
The loads on the discharge nozzle can be imported from the piping model. This will be the OPE case.
k Load Case Selection
[CASE 3 (OPE) W-K)i+J1 ?1?H

CASE 4 (SUS) W+Pl+H
CASE 5 ( EXP) L5 =L3 L4 -
Data | Suction Nozzle ] Discharge Nozzle Equipment Report
Nozzle Location (Rom Pump Center)
DX 0 000
DY 500000
DZ 300000
Forces on Nozzle
Global Force FX 6938000
Global Force FY 52Z 8000
Moments on Nozzle
Global MomentMX Z 9825000
Globol Moment MY -5567 000
-
Global Moment MZ 17226000
Select Leeds Job end Load Case O \TRAINING\CAESAR ll\TUTOR C2

CASE 3 (OPE) W D1T1 P1 H
Now analyse the pump.
The suction nozzle passes OK. But the discharge nozzle fails.
x force = 6938.0 N. 3780 1.64 Passed

y force = -8237.0 N. 3113 2.65 Failed
z force = -5228.0 N. 4692 1.07 Passed
x moment 29625.0 N.m. 3525 6.46 Failed

y moment = 17226.0 N.m. 1762 9.77 Failed
z moment = -5567.0 N.m. 2576 2.16 Failed
The load in the local Y direction (global Z) is excessive as are all three moment terms. The worst
component is the local My (global Mz) which is almost 10 times the Table 4 limit.
(
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Fix Model - Part 1

We need to know what is causing this large load. Return to the piping model and again view the
results. Review the Restraint summary for the OPE and SUS (installed) cases.
FY MY MZ
N. N. N.
10 Displ. Reaction
3(OPE) 6938 -522 B 6237 29B25 -5S67 -17228
4(SUS)
MAX
-270
6938/1.3
-
904
522B/L3
-0
8237/L3
-0
29825/L3
-0
-5 S 67 /L3
500
-17228 /L3
.
The large loads are present in operation but not at installation Therefore these excessive loads
are caused by the thermal expansion of the system. To reduce these loads we need to increase
system flexibility. There are two options to do this.
1. Model existing flexibility not currently in the model

2. Modifying the piping and/or support layout.
(
The most inexpensive modification would be to provide more modelling detail - modelling flexibility
.
in the system that is not currently included Welding Research Council Bulleting 297 provides
flexibilities for cylinder - cylinder intersections. These flexibilities may be applicable to the vessel
connection at node 110.
Include WRC 297 flexibilities

The vessel nozzle/connection is as follows:
Vertical vessel constructed of SA-516 Gr 70 .

OD = 1500mm (D), wall = 4.75mm (T)
Nozzle is 2200mm above skirt
Skirt is 3000mm above foundation
The long weld neck flange serves as the nozzle
OD=247.65mm (d), wall=22.225mm (t)
Nozzle pad is 4.75mm thick and 100mm wide
A tray is within 600 mm of the nozzle and a stiffener ring is 1000 mm on the other
side
Firstly we must evaluate the vessel/nozzle to check that the WRC 297 approach is valid.
( We have d and t ( relating to the nozzle) and D and T (relating to the vessel) described as above.
Below, T is the vessel thickness plus the pad thickness.
According to WRC 297:
D
/T < 2500 D
/T = 158 9 -c
20
d d
( Ceot cK
5 /T 100 /f = 26
d d
/t > 20 / t = 11 *
We will use this data even though it is outside the acceptable range
Apply the nozzle flexibility and complete the vessel/nozzle data in the Nozzles input.

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Restraints iZi Displacements

Hangars Flange Checks
[TlNozzle Flex MNozzle Lmt Check
The nozzle node is at 110 (recall that the nozzle is represented by the long weld neck). A valid nozzle
node has only a single element connecting to it (i.e. must have a free end) and also a nozzle node is
not restrained nor does it have any displacements specified. We have displacements applied at
node 110, for the vessel thermal growth. To rectify this we will specify a vessel node and apply the
displacements to the vessel node.
The vessel node is optional and works in a similar way to CNode described earlier. Give the vessel
node a unique number. In this case ours will be 1500. In addition, change the node the
displacements are acting on to 1500 as well.
Fill in the remaining vessel data, including the direction cosine - the vessel is vertical (Y ) so the Y
direction cosine is 1.
Type
o WRC 297
API 650
PD 5500
Nozzle Node 110
Vessel Node (optional) 1500

Nozzle Outer Diameter 247.650
Nozzle Wall Thickness 22.225
Vessel Outer Diameter 1500 000
Vessel Wall Thickness 4.750
Vessel Pad Thickness 4.750
Distance to Stiffener or Head 600.000
Distance to Opposite Stiffener 1000000
Vessel Centerline Direction Cosine VX
Vessel Centerline Direction Cosine VY: 1
Vessel Centerline Direction Cosine VZ:
I
Vessel Temperature (optional)
Vessel Material (optional): 1
Nodel : 1500
Vector 1 Vector 2 Vector 3 Vector

DX 0.0000
DY 8 4300
DZ -2 8700
RX 0 0000
RY 0 0000
RZ 0 0000

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This models the nozzle flexibility by inserting a zero length spring which is inserted between the long
weld neck flange (100-110) and the displacements representing the vessel thermal growth - which
we have now reassigned to node 1500.
Run the error checker. The WRC nozzle flexibilities will be calculated and included in the notes.
MOTE 110 WRC NOZZLE DATA FOR NODE 110

TERMINOLOGY :
--
D1 distance to stiffener or head
D2 distance to opposite side stiffener or head
.
-
L
D
T
d
-
unsupported length of cylindrical shell
L B(D 1)(D2) / [ sqt(Dl) + sqt(D2) J 2
---
mean diameter of vessel
wall thickness of vessel
outside diameter of nozzle
--
- --
t wall thickness of nozzle
capital lambda ", L / sqt( DT )
j
D1 - -
"lambda ", j (d/D) * sqt(D/T)
600.000 D2 1000.000
L
D
d

---1524.200
1490.500
247.650
12.609
T/t
T
t
0.427
9.500
22.225
2.081
CAUTIONS:
Lambda (j) Greater than 2.0 produces approx , rigid
junctions for longitudinal bending .
MOTH 110
- -
The following combinations produce rigid axial junctions:
-
j> 1.6 10 / j> 2.5 20 / j> 4.0 50 / j>6.2 > 100
WRC 297 NOZZLE CALCULATIONS

-
---
-- --
WRC NOZZLE NODE 110
VESSEL Dmean(mm.) 1490.500 VESSEL THR. (nun.) 9.500
N0ZZLE O.D. (nun.) 247.650 NOZZLE THK. (mm.) 22.225
AXIAL TRANSLATIONAL STIFFNESS ( KN./mm. ) 167.
LONGITUDINAL BENDING STIFFNESS (N.m./deg ) 29919 .
CIRCUMFERENTIAL BENDING STIFFNESS (N.m./deg ) 3720.
CAPITAL LAMBDA --
ANGLE BETWEEN NOZZLE VESSEL CENTERLINES(deg )
LENGTH (L) (nun.) 1524.200
12.809
THICKNESS RATIO
SMALL LAMBDA
-- 90.0000
0.427
2.081
The nozzle provides limited axial flexibility, but the longitudinal and circumferential bending
flexibilities appear significant.
Re-analyse the system and again review the results.
Review Results
These changes have not had any effect on the SUS case, and the EXP case is still below the allowable,
in fact the highest stress has now dropped slightly - as we have added more flexibility in the model.
The selected spring hanger is still a Carpenter & Paterson DV70, but the hot load has increased by
around 40N.
However, we were previously concerned with the pump loads. Review the OPE case restraint
summary. The loads on the pump ( node 10) have now decreased.
Load Case FX FY FZ MX MY MZ
NODE
N. N. N. N.m. N.m. N.m.
10 Displ. Reaction
3(OPE) 6753 -5749 7960 28632 -5383 -16491

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Run these new loads through the API 610 processor. Use the Refresh Loads from Current Job
button to bring in the new loads.
ut Data Suction Nozzle Discharge Nozzle Equipment Report

DX 499999
DY 0.000
DZ: 299.999
Forces on Nozzle
Global Force FX 6753 000
Global Force FY -5749 000
Global Force FZ 7960000

'
Moments on Nozzle
Global Moment MX. 28632.000
Global Moment MY -5383.000
Global Moment MZ -16491.000
Select Loads Job and Load Case D:\TRAINING\CAESAR ll\TUTOR _P

CASE 3 (OPE) WD1T1 *P1*H
CST Previously Retrieved Loads
The values have decreased slightly, but still the discharge nozzle fails.
Discharge Table 4 Force Moment Status

Values Ratios
x distance = 500.0 .
tnm
v distance
z distance
=
=
-300.0
0.0
mm.
mm.
x force = 6753.0 N. 3780 1.79 Passed

y force = -7960.0 N. 3113 2.56 Failed
z force = -5749.0 N. 4692 1.17 Passed
x moment = 28632.0 N.m. 3525 8.12 Fa.led

z moment = -5363.0 N.m. 2576 2.09 Failed

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Fix Model - Part 2

Return to the piping results and review the OPE restraint summary once again.
There is a rather large load on the guide (Z restraint) at node 75.
NODE Load Case

FX FY FZ
N. N. N.
75 Rigid Y; Rigid GUI w/gap

3(OPE) - 19130 4486 - 52810
The thermal growth of the long Z run from 80-90 loads the guide and pushes the elbow at node 70 in
the positive Z direction. This thermal growth increases both the pump load in Z and the bending
moment about X. Is the structure guiding the pipe as rigid as the CAESAR 11 model says it is? If the
guide has lower stiffness, the pump loads may reduce within their allowed limits. There may be
reason , then, to model the structural steel that is interacting with this piping system.
There are two structures - a frame under Node 75 and a T pole under Node 85. These structures will
be included in the analysis.
in ij?00
50$ '
[
i
>1
(2021) 300 1015
300 < 3t) 0
( 2020)
/ to
{ 005) 0
(201 )
I , 2010
I 2002
( KXXI )
2000)

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Build S'tcci Structure

CAESAR II includes a structural modeller. This module can be used as just described, to model steel
structures to support the piping in order to include the flexibility in the supports, as opposed to fully
rigid supports.
.
Return to the CAESAR II main window and create a new file Specify this as structural input.
Enter the name for the NEW job file

FRAME
Piping Input o Structural Input

piping files, even if they are to be combined for analysis
Enter the data directory

D:\TRAINING\CAESAR n ...
OK Help Cancel
The structural wizard will guide you through the process of setting up the structural file.
.
First the units to be used must be specified. Ensure that the Training units (TRAIN FIL) are selected
here. Click Next
Select a units file for this model TRAIN.FIL
On next screen, the vertical axis should be selected for the model, either the Y or Z axis can be set to
vertical. Select the Y axis as vertical and click Next
Selectwhich axis is vertical for this model | "

|
The following screen is to specify the material and material properties.
Any number of materials can be specified, each identified by a Material ID. For each material ID the
material properties can be specified. Within the steel modeller, each steel member is assigned a
material ID. Accept the defaults for material ID number one and click Next.
.
( The units are those from the specified * FIL from the first step) .

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169
Material ID 1
Density 7833440 Yield Strength 248 206
Young's Modulus 206838 000 Poisson's Ratio 0300
ShearModulus 75840 602
Expansion Coefficients
4 7
5 09
6 9
Add Another Material

/
Depending on your units, the default values you see may be different to those shown above - accept
the default values, do not change them to match the numbers in the figure. It will be the correct
value.
The following screen is to specify the steel members to be used in the structural model. Each steel
member is identified by a section ID and can be either selected from an included database of
sections, or can be User defined.
Section ID 1
NAME
User Defined?
| Select Section ll j
[jrj Add Another Section
In the structural modeller, each element can be assigned a section ID as well as a material ID.
We will use I-Beams in our model and will select from the built in database. Choose the Select
Section ID button and select the following I-Beams
Section ID 1: W 8 x 31
Section ID 2: W6 x 20

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i
a
*4
+ IHifcl-lfild
H Channels
SI Tees
S) Angles
+1 Structural Tubing
Search OK Cancel (
The final stage of the structural modeller wizard is to specify the method of element definition.
There are two options for this.
Method One - EDIM method, which is similar in concept to how piping elements are defined - a
start node and an end node are specified, along with the distance between the two to define the
structural elements.
Method Two - Node/Element method is a slightly different concept. Nodes are added and are
located at points in 3D space. Elements are then defined and users specify the nodes which each
element connects.
Select Method one and click Finish.
o Method 1 - Element Definitions
PX Use the EDIM option to define individual

elements which span between two node points
Method 2 - Node / Element Specifications

Use the NODE option to define a pattern of
10 nodes in 3D space
Use the ELEM option to conect the nodes with
elements

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The steel modeller will now appear with the options selected in the wizard added to the Card
Stack .
The Card Stack is a logical list view of the structural model where all parameters are listed and can
be edited.
Card Stack
Card Stack
* UNIT TRAIN.F1L
0 VERTICAL=Y
0 MATH) 1
matld 1
ym 206838000.0000
pois 0.3000
g 75840600.0000
vs 248.2056
dens 7833.4399
0 SECID=1 W8X31
0 SECID=2 W6X20
Now we will define the structure. As we have used the wizard to define the material and section IDs,
the next items we can define are the elements themselves. Use the EDim button to add a new entry
to the card stack.
| EDim [
From the sketch we can see that starting at node 2000, there are two vertical steel members, both
2500mm in length. These two members can actually be defined in one entry into the card stack as
they are identical.
Expand the new row in the Card Stack and first enterthe From and To node numbers as 2000 and
.
2010. Also enter dy as 2500 Specify the section ID and Material ID for this section also. Section ID
is 1and Material ID, as there is only 1is 1. We now have one element, from Node 2000 to 2010,
2500mm in length in the vertical (+Y) direction.
The inc, incTo and last fields can be used to duplicate this element quickly without adding a new
.
entry into the card stack The inc field will increment the "From node, starting with the original
.
"From node i.e. if we enter 10, the "From node on the second element will be 2000 +10 = 2010.
.
So in this case would connect to the first element The incTo is the same concept, but using the To
node. The last field is simply the to node on the last element to be defined.
Enter inc and incTo as 10 and the last To node will be 2020.

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EDIM 2000, 2010

from 2000
to 2010
inc 10
incTo 10
last 2020
dx
dy 2500.000 mm
dz
secID 1
matID 1
Continue and add a second Edim to the card stack. Define element 2010 - 2012. This time the
section ID 2 will be used.
EDIM 2010, 2012

from 2010
to 2012 (
inc
incTo
last
dx
dy
dz -1800.000 mm
secID 2
mat 1
The model so far should look like the following
zAx
(
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CADWorxe & Analysis Solutions
Tutor
Continue with 2002 - 2012. Again, this entry in the card stack will define multiple elements
3 EDIM 2002, 2012

from 2002
to 2012
inc 10
incTo 10
last 2022
dx
dy 2500.000 mm
dz
secID 1
matID 1
A
.
Add the finial members on the top As these are not identical, they must be defined as separate
entries in the card stack.
EDIM 2020, 2021 EDIM 2021, 2022

from 2020 from 2021
to 2021 to 2022
inc inc
incTo incTo
last last
dx dx
dy dy
dz - 300.000 mm dz - 1500.000 mm
secID 2 secID 2
matID 1 matID 1

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The final step is to anchor the steel at the base. Use the Fix icon to add a Fix entry into the Card
Stack, and fix at node 2000 and 2002. Fix in all degrees of freedom.
1AM
tj FIX 2000, 2002 ALL

from 2000
to 2002
by 2
x
x stiffness
y
y stiffness
z
z stiffness
rx
nc stiffness
ry
ry stiffness
rz
rz stiffness
all Fixed
all stiffness
The completed frame should look like the following.

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Save the frame. On saving the structural modeller will check the file. The following dialogue will
appear. Ensure that all three check boxes are checked .
J The input has been sav

v The input has been erro checked
v The execution files have been generotet
OK
Now create a new structural file for the T-post.
As before, follow the new structural file wizard. The T Pole is similar to the Frame in that it is the
same material and the same two steel sections used - W8 x 31 and W 6 x 20.
After completing the wizard, the Card Stack should again display as before with the same starting
entries.
Card Stack
B Card Stack
0 UNIT TRAIN.Fit
0 VERTICAL=Y
B MAT1D 1
maUd 1
ym 206838000.0000
pois 0.3000
9 75840600.0000
ys 248.2056
dens 7833.4399
0 SECID=1 W8X31
0 SEC0=2 W6X20
The first thing to note about the T Pole is that it is rotated 90. Add in a rotation angle of 90
\ 4 ?j
*
Card Star Angle |
ANGLE=90
angle 90.000
Continue and add in the elements
hM 1 EOim 1

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Tutor
1000 - 1005
EDIM 1000, 1005

from 1000
to 1005
inc
incTo
last
dx
dy 5000.000 mm
dz
secID 1
matID 1
The remaining horizontal elements will not be rotated 90, so add in another Angle and set this to 0
()
"
_
Card Stac Angle
- ANGLE=O
angle 0.000
The remaining horizontal elements will also all be Section ID 2. To save having to specify Section ID 2
for all elements, a default Section ID can be set.
3 rti
Default
Set this default section ID to 2.
DEFAULT 2, 1
Section ID 2
Material ID 1
Continue and add the remaining elements as follows
From To DX
1005 1010 -600
1005 1015 300
1015 1020 300
Finish off by fixing node 1000.
FIX 1000, 1000 ALL

from 1000
to 1000
all Fixed

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The completed T Pole should look like the following
zjkx I
Save the T Pole and again ensure that all three check boxes are checked.
\\ Model Generation Status*

0The input has been saved
The input has been error checked
[v] The execution files have been generated
OK

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CADWorx8 & Analysts Solutions
Tutor
Combine Pipe and Steel models

.
Return to the piping input We will now include the Steel models in the Pipe model. Select the
Include Structural Files button and browse to locate the two files just created.
s Wl Factor:
d)
cC -Mill Tal 54: 12 5000
Include structural files

Include structural Input
files
v
.
ir rahoi(agtttnftTre1uaira.t
File Name
Add
FFtAME , ,
TPOLE Replace
Delete
Edit
Browse
OK I Cancel
After Clicking OK the steel members will be included in the pipe file, however as there are no
common node points between the pipe and steel, the structural members are simply located at the
origin. We now need to move these structural files into the correct location.
A quick review of the pipe and steel model node numbers shows that pipe node number 75 will be
connected to steel node number 2021 and pipe node 85 will be connected to steel node 1015.
However the centrelines of the steel and pipe are not in contact, rather the bottom of the pipe is
resting on the top of the structure. The pipe and steel can be connected either way; connecting the
bottom of pipe with top of steel will be a more visually pleasing model, and in some cases (e.g.
where friction or a guide is included on larger diameter pipe) the proper contact point will affect the
results.
.
A dummy rigid element will be built at both support points to offset the pipe above the steel First
locate element 70-75. INSERT a new element AFTER this element. The new element will be from 75
to 1075 and the distance between these nodes will be -210 mm in Y. Make this a weightless, rigid
element.

(
INTERGRAPH
"
Tutor
>>
_
From
To
75
1075
. Name
Bend
Rigid
[ Expansion Joint

DX Restraints
DY ' 210 000 mm Hangers
Nozzle Flex
DZ
Forces / Moments
Offsets
YY Uniform Loads
Now return to the element 70-75 and redefine the restraint at node 75 by changing the Node to
.
1075 and define a CNode (connecting node ) of 2021 Now that the pipe to 1075 is in Y, the Guide
must be replaced with a 1 restraint (a Guide makes both X & 1 on a Y pipe). Be sure to do this for all
restraints at this point.
(
Node 1075 CNode 2021
Type Y T Gap
Stif Mu 3.000
Type Z Gap 8 000

'
Stif Mu 0.300
The frame will now be moved to connect to node 1075.
1
c f
Li
Repeat this procedure for the restraint at 85, creating a new element 85-1085 and connecting 1085
to 1015.

INTERGRAPH
'
Tutor
180
Type v " Gap

Slil 1 Mu 0.300
From
To
r Bend
0Rigid
1085
Expansion Joint

DX I Restraints
Hangers
DY -210 000 mm
Nozzle Flex.
DZ
Forces / Moments
OHsels
Uniform Loads
-
rs . m n n * jr A
The completed model will show the steel structures supporting the pipe as below.
101
S fc
Ui
Re Analyse the system.
(
(
INTERGRAPH
*
Tutor 181
Review Results
The SUS case has increased very slightly, but the EXP case has dropped down to 38% This is because .
.
further flexibility has been added to the system Specifically the stiffness at node 75 which was a
.
rigid guide now matches the frame stiffness The OPE displacements report shows that the 8mm
gap on the Guide (now the Z restraint) is closed, but then the guide itself shifts another 8mm in the Z
direction, rather than being stationary as a rigid. Note the displacements on nodes 1075 and 2021.
DX DY DZ RX RY RZ
nun. mm. mm. deg. deg. deg.
n n
1 ? -n 6 9 6 n 06 =; _ P 6 6d
_n n 9Q 6 n 6696 n nn6Q
[ 1075 -9.731 -0.134 -16.387 -.
0.1596 -.
0.4683 0.3627
TUBS
1500
-13.100
-0 . 0 0 0
0.029
8.430
*
--
14.441
2.870
-~ -
O 1412
0.0000
U IBIS
0.0000
'
-
"" U .1432
0.0000
2000 -0 . 0 0 0 0.000 -0 . 0 0 0 -0.0000 -0 . 0 0 0 0 0.0000
2002 -0 . 0 0 0 - 0.000 -0 . 0 0 0 -0 . 0 0 0 0 -0 . 0 0 0 0 0.0000
2010 -1.783 0.068 - 3.387 -0.0917 -0.0436 0.0735
2012
9 n?n
--0.416
6 606
-0.077
n no 7
-3.387
-P 9P 9
--0.0914
f> 7 9 P
-_0.0436
n 1947
0.0173
n n Q7 7
| 2021
2022
-4.988
-1.342
-- 0.134
0.111
- 8.387
-0.36B
-0.0730
-
0.0183 -0.1359
-0.1408
0.0853
0. 233
The restraint summary for the OPE case shows a significant reduction on the operating loads on the
pump nozzle.
FX FY FZ MX MY MZ
10 Displ. Reaction
3(OPE) 3113 -3663 1202 2650 -4816 -5139
As before, run these new loads through the API 610 processor (use Refresh Loads button to bring in
the new loads).
The discharge nozzle now shows that only the moment about the Y axis (global Z ) exceeds the
allowable limit.
Values Ratios
x distance = 500.0 mm.
y distance = -300.0 mm.
z distance = 0.0 mm.
x force = 3113.0 N. 3780 0.82 Passed

y force
z force
=
= -- 1202.0
3663.0
N.
N.
3113
4892
0.39
0.75
Passed
Passed
x moment = 2650.0 N.m. 3525 0.75 Passed

z moment = -4816.0 N.m. 2576 1.87 Passed
Adding the steel effectively increased the guide's gap. This greatly reduced the pivot action and the
resulting pump load.

IN i UKUKAPH
"
Tutor
Fix Model - Part 3

The only issue with the model now is that the local Y moment, global Z moment on the pump
.
discharge nozzle ( node 10) is excessive Without changing the position of the pump or vessel nozzle,
or changing the thermal strain, the only way to reduce these loads is to add flexibility to the layout.
There is no inherent flexibility that was excluded from the model so an expansion loop will be
introduced.
How big a loop is required and where should it be placed?
Expansion loop legs should be perpendicular to the thermal growth causing the load. We will focus
.
on the Z axis bending moment This bending moment is being caused by the +X force - the thermal
growth in the X direction (element 70-75).
Fx
Therefore the loop can be added in the Y or Z direction (perpendicular to X ). Which is the best loop
layout ?
Layout A - A loop in the Z direction at the end of the X run ( node 80)
Layout B - A loop in the Y direction at the end of the X run (node 80)
Layout C - A Y loop on the opposite end of the X run ( node 70)
(
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INTERGRAPH
*
Tutor
183
The bending stress at the nozzle is estimated using SEj =

'/ 3
SE / = stress range in legj (leg j is orthogonal to the direction of thermal growth to be absorbed )
Lj = Length of leg j
Li = length of leg i ( leg i represents each leg helping to absorb the thermal growth )
We know that
M MR
S E ) - J ~ 1~
6 EIALj
So let 6EIA = K
C Therefore solving for K using the current M (MZ Bending moment which is 5139 Nm ) and L| and L)
Lj = 4200mm
L, = LI 6205 mm & L2 4200mm
KLj
M
7
5.139 (62053 + 42003 )

4200
K = 383 x 106
Keeping K as a constant, we can attempt to reduce M. To do this we will increase the length of the
leg in the three layouts mentioned previously and recalculate M
The following table and graph summarises this.
Added Loop InZ In Y Riser Max Mz

Leg (m ) (Layout A) (Layout B) (Layout C) (= 2 * Table 4)
0 5.153 5.153 3.525
1 3.591 5.120 5.248 3.525
2 2.542 4.902 4.907 3.525
3 4.395 4.326 3.525
4 3.657 3.686 3.525
5 2.865 3 092 3.525
Red = above max Mz

Green = below Max Mz
c
<
INI tnuKAPH
'
Tutor
Effect of Various Loops

on Pump Moment - Mz
6
Riser
(Layout
C)
In Y
(Layout
B)
- inZ
(Layout
A)
> Max Mz
(= 2 * (
Table 4)
o t 1
0 1 2 3 4 5
Added Loop Leg (m)
As can be seen, the most effective way of reducing the MZ moment is to use layout A - an expansion
loop along the Z axis. This increases L, which is cubed in the equation so will have a much larger
effect of the MZ Moment.
According to the calculation, slightly over lm run in the Z direction is required, however this simple
equation does not take into account any rigid elements or elbows, nor does it consider any
intermediate supports such as the guide at node 75.
We could insert a loop of lm in length and continue iterating the model until we find a suitable loop
length. However this can take time and finding an efficient loop design may involve several
iterations, even on a simple setup such as this. CAESAR II provides a Loop Optimisation Wizard to
automatically size and create an expansion loop to get the most efficient loop for the target data.
(
INTERGRAPH

Tutor
Loop Optimisation Wizard

Return to the model and use File > Save As... to create a new iteration of the model with an
expansion loop. After performing the Save As... the analysis must be run once again because the
Loop Optimisation Wizard uses existing results in modifying the layout.
Run the analysis and return immediately back to the input. The Loop Optimisation Wizard button
will now be available (if this button is ever greyed out then there are no results available for use -
rerun the analysis).
Select element 75-80 as this is where the loop will be placed and click the Optimisation Wizard
button to access the wizard.
Jltg a T
-. J g
Optimization Wizard
The Loop Design Wizard will appear and the data required can be input in order for CAESAR II can
design the expansion loop.
The wizard will create iterations of a loop setup in order to focus in on a specific Stress value or
Restraint load. We wish to reduce the Restraint Load on node 10 to below the allowable for API 610
table 4. We will reduce the load to 3300Nm (currently the load is around 5150Nm).
The loop will be located on what is currently the element 75 - 80. This will therefore be as in Loop
Layout A.
The final thing to define is the space allowed for locating the loop. A cube of space can be defined
which the loop will fit inside. The Wizard will create the largest loop possible in the available space,
and if this is below the specified target load, the wizard will continue iterating to create the most
efficient loop possible, as close as possible to the target value.
In the Loop Design Wizard, select the OPErating Load Case and choose the target data to be
Restraint Load.
Load Case
Stress
3 (OPE) W+D1+T 1+P1+H
o Restraint
As we already have element 75 -80 selected, this element will be selected anyway.
The table will be filled in with the results data. Double Click in the MZ cell on the Node 10 row. This
will fill in the Node and Type fields. Enter 3300 as the data in the Load field.

INTERGRAP H CAESAR II Statics Training
Tutor m86
*
Loop Design Wizard
Load Case
O stress
3 (OPE) W+D1+T 1+P1+H
Restraint
targetData Create Loop On Element
Load Max Stress At Node Type
3300.000 |IB \\m 75 - 80
Loop Type
. ll.m. ll.m. il.m.
FX FY FZ MX MY MZ
llode
II . II. II
of op ot
<
-.)J
10 3118 3665 1201 2650 - 4816 -5159
-2927 19149 - 3646 998 M33 I
/ <f
110 -2393
1500 -2393 - 2927 19149 - 3646 998 4233 o
of of o\
Bend Cost Factor :
Height to Width Ratio: <none >
Specify the Loop Type as the centre loop type - this matches the type A that we have already
determined is the most efficient. The final option in the loop type section will allow the wizard to
evaluate all of the Loop Types and determine the most efficient. This takes longer as 8 loop types
are defined.
Also in the loop type section, change the Height to Width ratio to <none> to allow the height to vary
as needed.
Loop Type
of o f o?
<
O f |[ / |j O
C f
Bend Cost Factor : i00.000
f Height to Width Ratio: <nore > -
Finally the space available for the loop must be specified. Click the Draw Cube button. A cube of
space will be shown in the model. Currently this will be facing the wrong way. Click and Drag the
point labelled PT3 to reposition the cube in the correct orientation. On doing this the Major
Direction field will change to -Z. Increase the size of the cube in the -Z direction to ensure that
there is enough room to design the loop .
Cube of Clear Space
Draw Cube
Starting Point: X, Y, Z
3000.0001 4200.000 rr 0.000 mm
Major Minor Element

Direction Direction Direction
l -z H
I 2697.909 n I I 1200.000 n I I 1200.000 n I

INTERGRAPH
Tutor
187
I
!
PI 2
< s
3
k
v~
Once finished , click Design . The wizard will run through a number of iterations and converge on the
defined target value .
Loop Design Monitor

*X
Building Proposed Loop
Evaluating Impact
Comparing to Target
Converging : -
3312 ; 4.5502
Loop Type 5 Iteration 3
Verification Stage
Run Setup
Building Proposed Loop
Evaluating Impact
Comparing to Target
Converging: -
3291 ; 4.5800 =
Loop Type 5 Iteration 4
Verification Stage
Run Setup
Bi riWifwn Drnnnrad I nnn
Loop Type 5 Iteration 4 I farw*i I
Once complete the loop will be added into the model automatically. A confirmation message of the
total length of pipe and number of bends is displayed
Total length of pipe added = 3072.78 mm .

Total bends added 2
I OK I

INTERGRAPH
Tutor
188
The loop wizard has added an additional ~3070 mm of pipe. Split between the two legs to the loop,
each leg is now ~1535 mm longer. Our quick hand calculation indicated a length of just over lm, but
as noted previously this did not take into account rigid elements or elbows, nor does it consider any
intermediate supports such as the guide at node 75. In addition, we used a target value slightly
lower than the Max Mz as in the hand calculation.
For simplicity, round up the length of each of the two new legs to 1600 mm. With even more
flexibility, the MZ moment at node 10 will be lower still.
Re- run the analysis.
7
77
D 22
010 P
(
0
312
i
U b02 \ \ n
Ufcoo
o
Code Checks:
-
SUS Max stress is now 16% at node 68. Node 68 is the top of the riser. Recall how CAESAR II adds
intermediate node points around the bends as discussed in the TURBO example.
EXP - Max stress is 34% located at node 78. This node is the far end of the elbow at the start of the
long Z run
Hanger Sizing:
Carpenter & Paterson DV 70 size 11 hanger is still selected . The hot load has decreased slightly.
THEORETICAL ACTUAL
NO . FIG . VERTICAL HOT INSTALLED INSTALLED SPRING HORIZONTAL
NODE REQD NO . SIZE MOVEMENT LOAD LOAD LOAD RATE MOVEMENT
1 1 i ! ( ram . ) i (N .| ! (N . ) (N . ) ( KN . / rara . ) .
( nun )
70 1 DV70 11 16.940 6307 . 7815 . 0. 0. 2.059
CARPNTRS PATRSON LOAD VARIATION = 15 %
Pump Load :
The loads on Node 10 look much better now :
, FX FY FZ MX MY MZ
NODE Load Case .
.
N. N. N. N.m. N.m. N.m.
10 Displ. Reaction
3(OPE) 2498 -3140 14 B 4 1323 -3511 -3264

INTERGRAPH
CADWonc & Analysis Solutions
Tutor
189
Re- run these loads through the API -610 processor once again
Values Ratios
x distance
y distance
500.0
-300.0 v
z distance 0.0
x force 2496.0 N . 3780 0.66 Passed

v force -1484.0 N . 3113 0.46 Passed
z force -3140.0 N . 4892 0.64 Passed
x moment 1323.0 N m . . 3525 0.36 Passed

y moment 3264.0 N m .. 1762 1.85 Passed
z moment -3511.0 N m . . 2576 1.36 Passed
This time all loads pass on the discharge nozzle. The local My ( global Mz ) is now 1.85 times the
allowable ( we have used the 2 x table 4 approach ) and so now passes.
Overall Pump Status ** PASSED **
We have reduced the load on the pump by adding flexibility into the system in the form of an
expansion loop. The addition of this loop required an extra 1.6 metres of space. What if this space
was not available?

INTERGRAPH
Tutor
190
Fix Model - Part 4

We will now return to the model without the expansion loop and once again attempt to reduce the
load on node 10, this time assuming that there is no space available for addition of an expansion
loop. In this case we will add in an expansion joint instead to add in flexibility.
Open TUTOR.c2 (the file before the expansion loop was added ) and save as
_
Tutor Expansion_Joint_Check.c2
We already know that the issue with the pump is the Mz moment. This moment as we have seen is
caused by the thermal growth of 70-75. This horizontal displacement at node 70 causes the bending
moment.
X
z* x
- Mz
As such we wish to prevent this horizontal growth from being applied to node 10.
We will include an expansion joint to absorb this horizontal growth. Adding the expansion joint just
above the pump will best absorb this growth.
What type of joint should be used? As we are only trying to absorb movement by lateral deflection
only and there is no axial deflection or relative bending rotations at the joint ends, a tied expansion
joint will be suitable.
First of all we need to know the horizontal deflection that we have to absorb. We will use CAESAR II
to determine this by breaking the system above the pump and viewing the displacements report.
The value we obtain from this can be used to select the number of convolutions in the expansion
joint.
Select node 20 to 30 and change to 21 to 30

From 21
Name
To 30|
The system will now have two sub-systems sharing the same origin. We need to reconnect 20 and
21.

c
INTERGRAPH
*
Tutor
Add a Y restraint at node 20 and specify node 21 as a CNode.
Node S3 CNode 21
Type Y Gap
Slif Mu
We also need to prevent any rotation at this point as well. Specify three rotation restraints (RX., RY,
RZ ) at node 20, CNode 21
Node 20 CNode 21
Type fix E Gap:Q

Stif Mu
( Node 20 CNode 21
Type RY Gap
Stif Mu
Node 20 CNode 21
Type RZ ' Gap

Stif. Mu
Leave the transverse directions X & Z free to move. The system near the pump connection should
now look like the following:
l *

INTERGRAPH
0
Tutor
192
Re-analyse the model once again.
Using the EXP case Displacements report, we need to calculate the change in position between Node
20 and Node 21. Nodes 20 and 21 will move together in Y, RX, RY, RZ because of the Node/CNode
restraint definitions .
DX DY DZ RX RY RZ
20 - 0.000 2.321 1.150 -0.0000 -0.0003

0.0003 0.0002
21 33.433 2.321 11.446 -0.0000 - 0.0002
DX = 33.4 mm
DZ = 11.446 - 1.150 = 10.3 mm
This results in a relative horizontal displacement of 35mm.
This also shows a Mz moment of 4900Nm. This is quite a high load - as the system is completely
free to move in the X and Z direction, resulting in the largest displacement. If we were to introduce
some stiffness (as would be in the expansion joint itself ) this displacement would decrease.
2
Using the Senior Flexonics/ Pathway expansion Joint catalogue, we will select a 3.5 kg/cm class 150,
8 expansion joint. The catalogue shows a 20 convolution expansion joint provides 38.8mm lateral
.
deflection This satisfies our requirement. However this expansion joint also adds a lateral stiffness
of 6kg/mm or 58.7N/mm.
If we introduce this stiffness, the deflection would reduce. Reduced deflection drops the required
number of convolutions and, in turn, increases the stiffness between nodes 20 and 21 .
This iterative process can continue until the deflection test fails or the pump load becomes too high.
Add the final two restraints (X and Z) between 20 and 21. Set stiffness to 58.7 N/mm - use the
tooltips to check the units if necessary
Node: 20 CNode 21
Type X | - Gap
Slit 158.7 Mu:
ITl.m./deq < or > N./ mm. |

Node: 120 CNode 21
Type Z F Gap
[
Slit. 58 7 Mu

INTERGRAPH

Tutor
193
Re running the analysis and viewing the EXP case displacements shows the new relative lateral
displacement of around 21mm.
The OPE restraint loads show that the MZ has now decreased drastically and is now around 25% of
the previous value.
NODE Load Case FX FY FZ MX MY MZ

N. N. N. N.m. N.m. N.m.
10 Displ. Reaction
3(OFE) 1191 -3053 394 67 -6157 1063
.
However, the MY is excessive at over 6000Nm This moment will also place torsion on the expansion
joint and this torsion may also be excessive .
If this observation did not stop the iteration, how would this process proceed ?
Test 16 convolutions - 16 convolutions allow 24.8 mm lateral deflection and has K = 118
N/mm
Reset X and Z restraint stiffness to 118 and reanalyse
Check travel limits for the proposed joint and the load limits for the pump.
If 16 convolutions is OK and overall joint lateral translation drops, test a shorter (i.e., fewer
convolutions) joint.
In conclusion, because of the large global My on the pump and the torque on the expansion joint,
the proposed length and location of this joint should be reconsidered.
For the purposes of this exercise, analysis of a 20 convolution, tied expansion joint will be evaluated.
For this length, a tied universal joint would probably be preferred; consult manufacturer for other
options.

/
INTERGRAPH
0
Tutor
194
Model the Expansion Joint Assembly

The flanged expansion joint would be located between the discharge nozzle and the existing weld
neck flange. To save time in this examination, the expansion joint will be placed between the flange
and pipe rather than between the nozzle and flange. The error introduced will be small.
.
Return to Tutor c 2 and rename as Tutor with Expansion Joint.c2
Select Element 20-30 and access the Expansion Joint Modeller.
0Y 900.000 mm
E3 DZ:
Offsets
EK-
Expansion Joint Modeler
i
Expansion joint modeler
u I oculll V E
W1 Factor r
Select to create an expansion joint with the following properties:
T
Pressure 50 pound
Style Tied
Convolution Material 304SS r
# Convolutions 20 /
End Type Slip on ( Both Ends) ~ a-
o
O
.
ir 'BTmCT Whi>rafeibiTa'sai3Tfarfaaiii r s js
nf
Pressure Style Convolution Material # Convolutions 'To" End Type "From" End Type
25 Untied A WELDED WELDED
ETu 316SS 6 m\mu I MlllSMgl \
150 Hinged 600tnc 8 WN WN
300 Gimbal 625ln 10 Plate Plate
U-UNIV 12
-
T UNIV 1A
b
16
18
m-
Temperature Liner Cover

~
IgPTim 1
Sid Std
Heavy Heavy
[ OK Cancel

INTERGRAPH
0
Tutor
195
After clicking OK, CAESAR II will split the selected element to fit in the expansion joint. Which end of
the element to place the joint must be specified. We will split at the From end ( Node 20).
Place joint at WHICH end of element?
'9 From O To
OK Cancel
The temperature of the element in question is 315C. Apply this temperature to the joint, which will
subsequently cause the stiffness to be adjusted.
o Highest element temperature = 315.0 degrees.

Adjust JOINT stiffness to temperature?
Yes No Cancel
The expansion joint modeller will finally confirm the creation of all the elements to be used in
creation of the joint. The stiffnesses will also be displayed, along with the Allowed Movement.

INTERGRAPH
Tutor
Expansion Joint Modeler
Proposed Model
-
Expansion Joint type SINGLE TIED
Length Weight Type
From To mm. N.
20 21 450 206 387 Rigid end piece
21 22 317.500 0.000 Bellows Element
22 23 450 206.387 Rigid end piece
20 24 406.400 0.000 Tie-bars
23 30 493.600 0.000 Std. Pipe
As-Tested
Bellows Catalog Data
Adjusted Allowed
(
Direction Stiffness Stiffness Movement
KN / mm KN / mm mm.
Axial 0 0 87 884
Lateral 0 0 38.862
Angular 9 9 10.000
Torsional 7102 7504 0 212
Build Cancel
Click build and CAESAR II will attempt to define the expansion joint using the data supplied/obtained
from the catalogue.
'
x-'Jj
Error
) Expansion Joint installed successfully.
OK

INTERGRAPH

Tutor
197
Axial Stif 0.073
Trans Slif 0062
Bending Stif
Torsion Stif 7504268
Effective ID 239.794
Re analyse the system.
Using the Expansion Case displacements, calculate the lateral deflection between nodes 21 and 22
the nodes on either end of the expa nsion joint.
.
DX = 20mm; DZ = approx 12mm. The overall deflection is therefore around 23 mm .
The Flexonics catalogue shows that this displacement is acceptable for a 20 convolution joint.
There is minimal Axial deflection (DY = approx. 0.3 mm) and Angular Rotation ( RX and RZ = Omm).
. .
Torsion in the joint is 0.3 degrees The catalogue actually shows that this torsion is excessive

INTERGRAPH
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Tutor
198
Document the Analysis

The analysis is now complete, and the model is acceptable. We will work with the model including
the expansion loop, rather than the expansion joint.
The stresses are all acceptable and well below the code allowables. The loads on the pump are also
all acceptable and below the allowables for API 610.
We can now document the analysis and produce a report which could be supplied to a client,
including a plot of the system and annotated stress isometrics .
Custom Reports
In addition to these, custom reports can also be created.
ai ;
I Add new custom report template |
Custom reports are created using the Report template editor .

Edit Report Template.Untiled Preview Report Template;Untitled
*
Template Name
Templet Hem Untitled
CAESAR II 2011 SP1 .
Ver . 5.30 01, (Build 110228 ) ,
Date ; JUL 21 2011 Tine: 16:15
* *
Templet Description Job: D: \ TRAINING \ CAESAR II\ TUT 0R WITH LOOP
*
Report Typ IndxMoa! Licensed To: Seat ID 51
*
Template Settings UNTITLED REPORT
Header CASE 3 ( OPE ) W+D1+T1+P1+H
Report tleme r Indud Report flam

* * SAMPLE REPORT IS LIMITED 70 THE FIRST 50 LINES OF OUTPUT
load Casa llam (s )
* * Indude Load Case Ifamefsl
Fitter
* * Indude Filters Description
Align Header Lines kft
Body
Body Font Courier Hew lOpt
MigMigW/ Erref Font 1 1 Courier Hew. Kpt
Align Column Text left
Report Unt Spacing 1.0
Summary Una v Include Summary MAX Une
Displacements
Restraints
Local Restraints
Equipment Ho ate Check
Global Forces
Flange Evaluation
Stresses
Hanger Table
In the report template editor, a new report can be created by adding in all the columns you require .
Any column from any report section can be selected.
The following sections are available. The individual columns from these reports can be added in any
order as required.
* Displacements
Restraints
[]
0 Local Restraints
0 Equipment Nozzle Check
0 Global Forces
0 Local Forces
0 Flange Evaluation
Stresses
Hanger Table

INTERGRAPH
Tutor
199
In addition to setting the column order, various other properties on each individual column can be
set. These properties are as follows:
Displacements
OX
Column Order 0
Precision 2
Sort Order none
Font |Courier New; lOpt
Align Values right
Field Caption OX
Column Width -1
Units Based Precision N
Units Conversion Label
As well as properties for each individual column, report wide settings can also be set .
- Template Settings
- Header
Job Name v Include Job Name
Report Name </ Include Report Name
Load Case Name(s)
Filters
*r Include Load Case Name(s)
< Include Filters Description
Header Font |Courier New; lOpt
Align Header Lines left
G Body
Body Font H~ Courier New; lOpt
Highlight/Error Font T | Courier New; lOpt
Align Column Text left
Report Line Spacing 1.0
Summary Line v Include Summary MAX Line
Node Number/Name Print Node on Each Line
The template can be either an individual report (one load case per report) or a summary report
(multiple load cases per report). Or a Code Compliance report ( detailed information on calculated
values vs allowable) or a Nozzle check report (Displays nozzle loads if present).
Template Name
Template Description Stress Summary Report including Max

Report Type Summary
SJxesses and overall review of each
We wish to create a custom report which shows the stresses in the EXP case and the SUS case similar
.
to the Stresses report View this report for the EXP and SUS cases .
The issue here is that two reports are created, one for each case.
1 VV -
J . i CJ
|(4)Stresses (5)Stresses
.
But we wish to view both cases in one report This therefore would need to be a Summary report.
View the stress summary report for both of these cases.
This report displays the max stress for each case in one report, but does not display the stresses at
each node, like in the stresses report. We need a summary report which shows data at each node.
/
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Create this as a custom report. So that we can view sample data in the report, select the load cases
as well before accessing the report template editor.
Load Cases Analyzed

l (HGR) CASE NOT ACTIVE
2 (HGR) CASE NOT ACTIVE
S (OPE) W +D1+T1+P1+H
4 (SUS) W+Pl+H
-
5 (EXP) L5 =L3 L4
I Add new custom report template |
First of all give the report a title Stress Summary with Detail . The report template preview will
.
update to show this Also change the Report Type to Summary .
Q Template Name
Template Name Stress Summary with Detail
Template Description
Report Type Summary
The report itself we wish to be shown in a nicer to read font that Courier. Select Calibri, llpt text
and align the column text to the centre of the column to ensure everything stays inline.
0 Template Settings
0 Header
Job Name v Include Job Name
Report Name v Include Report Name
Load Case Name(s) v Include Load Case Mame(s)
Filters v Include Filters Description
Header Font J/l Calibri; llpt
Align Header Lines left
Body
Body Font II Calibri; llpt
Highlight/ Error Font H Calibri; llpt
Align Column Text center
Report Line Spacing 1.0
Summary Line v Include Summary MAX Line
Node Number/ Name Print Node on Each Line
Now we can add the following columns into the report, in the following order:
1. Bending Stress
2. Torsion Stress
3. SIF in Plane
4. SIF Out Plane
5. Code Stress
6. Allowable Stress
.
7 Ratio %
8. Piping Code
Enter in the column number next to each column required. Also tick the Show Piping Code check
box.

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201
E Stresses
Highest Stresses Show Highest Stresses
Piping Code Show Piping Code
0 AXIAL.STRESS
0 BENDING STRESS _ 1
0 TORSION.STRESS 2
0 HOOP STRESS _
_
0 MAX STRESSJNTENSrTY
0 CODE.STRESS 5
0 ALLOWABLE STRESS _ 6
_ _
0 SIF IN PLANE 3
0 SIF_ OUT_PLANE 4
0 PERCENTAGE 7
The report preview should show a sample of the report.
. .
CAESAR II 2011 SP1 Ver 5.30 01, (Build 110228) Date JUL 21, 2011 Time 16 15
Job: D:\TRAINING\CAESAR U\TUTOR WITH LOOP
Licensed To: Seat ID # 51 -
STRESS SUMMARY WITH DETAIL REPORT: Stress Summary Report including Max Stresses and overall review of each node
Various Load Cases
Bentlin8 Stress Torsion Stress Code Stress Allowable Stress Ratio

NODE Load Case
N ./sq.mm . N /sq.mm
SIP In Plane SlF Out Plane
.
N /sq mm . .
N /sq mm %
4 ( SUS) 4.79 1.17 1.00 1.00 6.34 119.39 5.31 B31.3

5 (EXP ) 12.54 7.44 1.00 1 00 19.46 315.26 6.17 B31.3
MAX 12.54/ L 5 7.44/LS 1.00/L4 1.00/L4 19.46/L5 315.26/L5 6.17/ L5
4 ( SUS ) 13.61 1.17 2.16 2 55 15 31 119.39 12.82 B 31.3

5 ( EXP) 10.77 -7.44 2.16 .
2 S5 18.37 306.29 6.00 B31.3
MAX 13.61/ L 4 -7.44/L5 2.16/ L4 2 55/ L4 18 37/ L5 306 29/L5 12.82/ L4
Currently there is no summary table like in the Stress Summary report showing the max stresses.
Insert this into the report as well by checking the Show Highest Stresses check box .
B Stresses
Highest Stresses 0 show Highest Stresses
..
CAESAR IIMil SPl Ver S 30.01, IBuild 110238) Dele:IUL 21,11
Job:D:\ TRA1NINS\CAESAR ll\ TUTOR WITH lOOP
licensed To:Scat IDtSl
STRESS SUMMARY WITH DETAIL REPORT' Stress Summary Report incl
Various load Cam
Bending Stress Torsion Stress

NODE Load Casa N /sq. mm . N . / sq.mm.
SlF Hi Plane
Piping Code : 031.3 0313 - MOB, December 31, 2008
CODE STRESS CHECK PASSED LOADCASE 4 (SUS) WP1*M
..
Highest Stresses:(N / sq .mm. ( tOAOCASE 4 (SUS) W PKH
CodeSt ru Ratio (Ml: ISi Node U
.
Code Stress *
IB.5 ASowaWe: 119.4
Axial Stress: 2 7 Node 68
Bending Stress 16 0 ffNode 60
Torsion Stress. 4 6 QNode 77
Hoop Stress: 2 J 0Nodc 30
3 D Max Intensity 18.7 ffNode 6
Save the complete report.
Any custom reports created can be exported and then imported on any machine so that all users
have access to all reports.

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Tutor
Filters
We have created a new customised report to show the data we are interested in. View this report
for both the SUS and EXP load cases.
The report will look as we expected and show all the data we require. However there is a lot of data
.
as we have all the stresses at all nodes, in two load cases Reviewing the data shows that a number
of nodes have very low or even zero stress. We can filter this data out to display only stresses above
a certain value. Admittedly, our stresses are quite low throughout ( highest is only 33.5%), but we
still are not concerned with stresses that are only a fraction of a per cent for example. As such we
will filter the data so that any stresses <5% will not be shown.
Close the report and access the Filters Dialog from the menu.
|laB WH?) | Filler Opti
iBQ 13 8 B Modify Filters
.
The filters dialog allows the data to be filtered on a combination of fields and values The filters
work using Boolean algebra. As such, if multiple fields are required, you must select whether to
include an AND clause or an OR clause in the Filter options. Additionally, any values entered in the
filter can be either Absolute values - the modulus of the value is used (i.e. if =500 is entered, -500
and 500 will be classed as matching the filter)) or Signed values (i.e. if =500 is entered, -500 will
not be a match, but 500 will). The results can also be filtered on node numbers.
Filter Options Displacements Restraints Forces Stresses Ur
Filter Options Combinations

Fields
@ Absolute Value
OAND
O Signed Value @ OR
Classes
O AND
o OR
The filters can be combined by Fields and Classes. The Classes are the categories and are essentially
each tab in the filters dialog. The fields are the individual fields and are essentially each entry on
.
each tab. Any filters are only applied if the field filtered on is actually displayed in the report So if a
restraint load filter of FY > 1000N was applied as a filter, this would not be applied to for example
the displacements report - FY is not displayed in the Displacements report .
Create a filter to display, as mentioned previously, all stresses greater than 5%.

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Filter Options { Displacements | Restraints [ Forces Stresses Line Numbers
SIFs
Axial Stress j | |f In Plane
Bending Stress , W Out of Plane :
Torsion Stress
Code Stress
Ho o p Stress | | ] Allowable Stress [
'
MAX 3D Stress }* Percent . > | 1fiToooo 1
( Click Apply and now review the Stress Summary With Detail custom report for the SUS and EXP
cases.
The report will not show every single element now, only those which have stresses higher than 5%.
Generate Report
As we have seen, there are many reports produced by the CAESAR II analysis. All these reports can
be viewed on screen as we have been doing, or alternatively each report can be sent to Microsoft
Word or Excel, or a text file.
We can produce a full report document of the type which could be submitted along with the analysis
for approval.
For our report we wish to include the following information .

Input Echo
Load Case Report
sustained Stresses
EXPansion Stresses
OPE & SUS restraint loads
( OPE displacements at all nodes

Hanger Table with text
This is a simple procedure and is simply a matter of selecting the reports to publish which contain
the data we require and including them in the Output Viewer Wizard section of the output
processor.

-
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Review each of the reports mentioned above in turn to verify that the data is suitable. Start with the
Input Echo.
General Computed Results

Hanger Table
Hanger Table W/Text
BliSSBSHHK
Miscellaneous Data
Load Case Report
Warnings
The listing options window appears prior to the report being generated, where all input data can be
selected for inclusion in the input echo. By default CAESAR II picks the most relevant data depending
on the model input - i.e . if WRC nozzle flexibilities are included, this is ticked, if there were no WRC
297 nozzle flexibilities, this box would be un- ticked by default.
Report Options
(v) [Elements 0 Restraints 13 Nozzles (WRC 297)
B Displacements Nozzles (API 650)
B Bends El Hangers Nozzles (PD-5500)
Ranges Equipment Check
B Rigids
El Expansion Joints
C Reducers Forces B) Units
13 SIFs and TEE's 1 Uniform Loads E) Setup File
Wind /Wave B1 Control Parameters
v] Material ID Offsets [3 Coordinates
B Allowables Node Names El Title

Check the Items to Print or View and then click on OK
2K Cancel Clear
Select these defaults and click OK.
Review the Input echo to ensure that all data required is included.
Once happy with the contents of the input echo, close the report and click on the -> Add button to
add into the Output Viewer list.
General Computed Results Output Viewer Wizard

HangerTable
HangerTable W/ Text o Send to Screen Send to MS Word
llnput'Echo
Miscellaneous Data Send to Text (ASCII) File Se
Load Case Report v Generate Table of Contents (TOC)
Warnings
Show these reports in this order
( -> Add Input Echo GENERAL
<- Remove
r
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Repeat this process for each of the reports shown, including for the SUS and EXP stresses; add in the
custom Stress Summary with Detail report.
.
Once complete all reports we wish to publish will be in the list We will now send these to MS Word .
Ensure that the Send to MS Word radio button is selected and click Finish .
Output Viewer Wizard
Send to Screen o Send to MS Word Send to Printer

Send to Text (ASCII) File Send to MS Excel
V Generate Table of Contents (TOC)
Show these reports in this order
-> Add IlnputEclio ' GENERAL

Load Case Report : GENERAL
B Stress Summary with Detail : Multiple
<- Remove A (SUS) W+P1 *H
5 (EXP) L5=L3-L4
Clear All
B Restraint Summary : Multiple
3 (OPE) W*D1 *T1 +P1+H
A (SUS) W+P1 *H
Displacements : 3 (OPE) W*D1 *T1 *P1 *H
HangerTable W/ Text : GENERAL
Rnls
- V
Word will load in the background and CAESAR II will publish all the selected data. The results will be
inserted as tables into the Word document .
x i|
OutP 02 l
I Finished sending reports to MS Word document ..
OK
Once complete, review the Word document. Formatting can be applied as usual within Word.

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ISOGEN Stress Isometrics

In addition to the Word Document report, stress isometrics can be generated and annotated with
input/output data to supplement the report.
Stress isometrics can be configured so that the output appears as the user requires, if you have
company/client standards for isometric drawings, these can be set up and configured using the
ISOGEN l-Configure module supplied with CAESAR II.
.
We will set up l-Configure to use one of the default styles There are many switches which are
.
available to control the appearance and content of the isometrics These switches are not covered
.
in this course However, a number of Wizards are available for configuring common parameters.
l -Configure can be accessed from the CAESAR II main window, from the Tools menu.
Bn CAESAR II - [D:\TRAIN
\ File Input Analysis Output Tools , .
iiTtW,iri.-Tiz.4 1331 tSSD BH
iDe h
< @ Configure/Setup
Make Units files
Caovert Input to New Uoits
3 Material Data Base
Accounting
Multi-Job analysis
Invoke Alias Isometric Confiquratic External Interfaces
ICAO lOUIUCll ICS
0 ISOGEN Isometrics
to the Word Document re a I-Configure
nt rlata tr rnnnlomanf tho
The l-Configure window will currently be empty, as no styles will be set up.
St l-Configure IHI UrSSml

File Edit Wizards Tools Help
;Ms|gNMHbc| l IfeWlal + l - lml
Property lvalue
Overview Detail
m
JO
Jfi
D.\ WORK \ ISOGEN Exemp!eProject2 Check Empty

.

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Most of the buttons on the toolbar along the top will be greyed out.
Si I- Configure
File Edit Wizards Tools Help
Nsl I I I I I I I I I I I I 1
There will however be two buttons available; the first of which we are concerned with, in that this
.
button will be used to create a new Isometric directory (The second button is simply to connect to
an existing isometric directory ) .
ISOGEN uses a specific file/folder structure, at the top is the isometric directory. Contained within
the isometric directory is a number of Project directories. Each isometric directory can contain
multiple project directories. Contained with a project directory can be many style directories. As
above, each project directory can contain multiple Style directories.
Within each style directory are a number of files, each of which contain various different data for the
appearance and content of the isometric output (including the format of the output - *.DWG, *.DXF
.
etc ). These files are created by l-Configure I-Configure reads an XML file on selecting the current
style containing all the settings and then writes these settings to various files which ISOGEN reads
when producing an output.
Choose to create a new Isometric Directory.
Mai I 1 . :lLdh<k->| | a|
I |Create New Isometric Directoryl
We will create a new folder on the E:\ drive in which all the ISOGEN data will be located.
Browse to E:\ and create a new folder called ISOGEN and set this as the Isometric directory.
An additional button is now available which allows us to create the project directory.
[SS I- Configure
File dit Wizards loots Help
Mglgltjj. I 1 1 1 I I **
[HI IDSHHI Create New Project |
Within each project directory there must also be at least one style, so the template styles are
available to choose from.
Name the project TRN Project (spaces are not allowed) and select the Final Basic Style as the only
.
style to produce ( Un-tick all other styles) Change the Name column to Stress-Iso as well.

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Tutor
El Create New Project Ua l

*
Current Isometric Directory |D \ISOGEN
New Project Name |TRNPROJECT
Application
IDefault Zlt
Available Styles
JTemplate
Type
Optional
Optional
Optical
| Name
L Check
|2 Stress-Iso
C Final-Cut-List
Check
Final-Basic
Final-Cut-List
H
Optional C Final-Erection Final-Erection
Optional (21Final-Fab Final-Fab
Optional C Final-Weld-Box Final-Weld-Box
Optional [ Oveiview Overview
Optional Q Spool Spool
OK Cancel
IB g OAISOGEN
B & TRNPROJECT
| Stress Iso
Before we produce isometrics, let's check the output to see what an example isometric would look
like.
Before any style created in l-Configure can be used, it must be exported for use (as discussed above) .
Select the Stress-Iso style and click Export Style.
+ - Iml
0 g D:\ISOGEN Export Style]
0 Si TRNPROJECT
yggggg
I-Configure
.m Style Exported to location

D:\ISOGEN\TRNPROJECT\StressIso
OK
Next we can process a sample file through ISOGEN to get a preview of what the output would look
like with our style. To do this, select the Preview Isogen Output button.
laH - lujl
Prev ew isogen Output

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3 Isogen Preview nr n ~
Isogen returned 0
|
No euots
Rles generated (double click to view)

Rle Type | Rle name
lolaCTMIWi) sremi
MESSAGE Stress Iso.mes
MATERIAL. MATERIALMTC
< III _l l
View OK
( .
A sample output will be produced Select the Drawing preview.DXF and click View.
The resulting isometric will look like the one below. This is not quite what we want. We are
producing a stress isometric, so we do not need a Bill of Materials, and we also want a different
drawing border.
I I
N VMTglAt
r
UW - r/JRICATWH
p&s
asw
n.
UATOUL UST - CRECT10M
&
H
.
ra *
moiwmim
*
or ~
.
iSSniia
ALIAS
]
-
AI
MI IL 1
rvtew i /i I t
A sample drawing border already exists; we can use this sample border and turn the bill of materials
.
off
Copy and paste the file from E:\Training\Masters\A 2StresslSOBorder.dxf into the isometric style
directory E:\ISOGEN \TRNPROJECT\Stress Iso.

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Within l-Configure, select the current style and in the bottom left pane, select the Overview tab.
Highlight the Drawing Frame entry in the tree. This will take you to the TemplateFile variable in the
table in the right pane. Double click this field and browse to the new file to be used as the border.
B @ D \WORTMSOGEN Property Value
! ra . Q Stresslso BoBomMa/qin
D . \ WORK\IGN 2 TopMarqin
K S D.\WORK\ISOGEN\TEST LeftMarqin 10 mm
BSDVSOGEN 202 mm
i a Q TRNPROJECT
.
CustomHeiqhl 0 mm
BS \WORK \ISOGEM\P 1
Igi I
DXFUnits MM
-
a t] Sample ResaiyedAraoDiawing
ReservedAreaDtawingToo 0 mm
Overview ReservedAreoMolist 0 mm
TemplateFrie ISTYLE$\A2SlresslSOBorder cW
Q] B 3Cj
Stress Iso
TemplateFormet AutoCAD DXF (DXF)
B Drawing
t |- cff Output Format AutoCAD OXF (DXF)

(S
fS Drawing
1
:e A2
Drawing Size 1
From * tSTYLE $\A2StresslSOBorder dxf

ig Frame
-
Eff Plot File Path $S7YLE$ \Orawmgs \
- ESP
Visiblo IFalse
El Specify path for file
Cff IsometricType Combined
Combine
-
- cff North Direction Top Lett
BlSTrlE$\A2StiesslSOBorder di
(
?
$ Units * Metric
-/
Cff Material Usl True
Cff Weld list Folse
InchBores
_ Cff Cut List False

B J Reports
We have now specified our custom drawing frame, as we will not require a Bill of Materials on our
Isometrics, we have a little more space available for the isometric plot. Increase this space by
reducing the drawing margin. Currently the drawing margin on the right hand side is 202mm. The
left margin is only 10mm. Make these equal by changing the RightMargin to 10mm also. ISOGEN is
now allowed to use the space that was previously taken up by the BOM as extra space for the plot.
Property Value
BottomMargin 50 mm
TopMergin 9 mm
LeftMarqin 10 mm
RightMargin 10 mm
Finally we must now turn off the Bill of Materials. Still in the Overview tab, select the Material List =
True entry in the tree. Again, this will display the relevant variable in the right hand list. Change this
value to False .
SmallxLargeNS
SpoolsMatchFull False
TextFont
Visible False
WastaaeArea 1
Save the changes and Export the style once again so that we can see the results of these changes.
B D D:\ISOGEN Export Style]

El > TRNPROJECT
METy 0 ;r|
IM I 1 1
Prev ew Isogen Output

INTERGRAPH
Tutor
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axi
pt
< 9.101
u
ow.
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I
a
ty
01
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x
turn
imit.
TIRE3
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INTERGRAPH jggjxi
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This output looks acceptable. Save and close l- Configure and return to CAESAR II.
I-Configure is now set up and we can now use the ISOGEN module in CAESAR II to annotate and
produce stress isometrics.

INTERG
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Tutor
From the CAESAR II main window, access the ISOGEN isometrics module
File Input Analysis Output Tools Diagnostics ESL View Hel

:D B 0 S Configure/Setup
Make Units files
Convert Input to New Units
& Material Data Base
Accounting
Multi-Job analysis
External Interfaces
Ready
0 ISOGEN Isometric
! \gj I-Configure
.
CAESAR II will open the model for isometric production Click OK to confirm and continue.
Opening CAESAR D model for Isometric g zneration,

click OK to continue.
OK
The model will be shown and can now be annotated
! Create Isometric Drawing * Edit Stress Annotations Une Number Filter Save Isometric Template j
Annotating the model involves simply selecting which data to include in the annotations, and is
simply a matter of ticking the required data. All input data can in included as follows.
1Allowable Stress DM
Bend Data
Diameters
Displacements
Equipment Notrle
Expansion Joint Data
External Forces / Moments
Flange Data
Fluid Data
Insulation Thickness
Line Number
Material Name
Node Numbers
Nozzle Data
Pressures
Restraint /hanger Types
Fligid Weights
SIF/ fitting Data
Temperatures
Uniform Load
Well Thickness
Wave
Wind

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All analysis data can also be included as well. For each load case run, the displacements, restraint
loads and stresses can be specified, as well as hanger data.
In addition to input and output data, custom annotations can be added to any node number or on
any element. Project attributes can also be specified and placed on the resulting isometric.
We will annotate our isometric with the following data:
Input:
Node numbers
Temperature T1
Pressure PI
Output:
SUS Max stress ( node 68)
EXP Max stress (Node 78)
Nodal Annotations:
Node 10 - PUMP A CONNECTION
Node 110 - VESSEL D CONNECTION
Elemental Annotations:
Element 100 - 110 - LWN Flange as Nozzle
Project Attributes
Project Name TRN
Project N 001
Client Name TRAINING
Area T1
System TUTOR
Prepared By <enter initials>
Select to Eit stress annotations to bring up the annotations panel .

j Create Isometric Drawing
- Edit Stress Mriotations Line Number Filter Save Isometric Template
Edit Stress Annotations
From the panel select Input data and choose Node Numbers from the feature drop down list. We
wish to annotate all the node numbers. However, as we have discussed previously, CAESAR II
automatically splits bends and inserts intermediate nodes. We do not wish to annotate these
intermediate nodes. As such, select all nodes except the intermediate bend nodes. These bend
nodes should be as follows:
68 69 79 81 82 83 84 118 119 148 149
Select all nodes except those listed above. If you wish, return to the input and check which nodes
are the intermediate bend nodes on your model.

INTERGRAPH
*
Tutor
Feature
[Node Numbers
Select | Node # | Node Nami
1 0 10
2 20
3 0 30
4 0 40
5 50
6 0 60
7 68
8 69
9 70
10 75
11 0 76
12 77
13 0 78
14 79 /
15 0 80 \
16 81
17 82
18 83
19 84
20 0 85
21 0 90
22 0 100
23 El 110
24 118
25 119
26 120
27 0 130
28 0 140
29 148
30 149
31 E 150
32 0 1075
33 0 1085
Once completed, select Temperatures from the feature drop down and select Tl Do the same for .
Pressure PI.
Feature
(
iia'iirran.ttiTfiEi
~~
: Feature
Pressures
Annotate Temperatures
Annotate Pressures
Select All Select All
0T-1 j p-1
We can now specify the output data. Select Output tab and pick the SUS load case. Select the Stress
option. The highest stress for the SUS case is on the bend at the hanger ( node 70) - the stress is
actually at node 68, but this is not selectable in the list. Node 60-70 is selectable and will annotate
correctly. Pick this node.

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Tutor
o Load Cases Hanger Data
CASE 4 (SUS) W+P1+H

Results
Displacement
Restraint
Select | From # | From Name To #

1 20
2 i 20 30
3 30 40
4 40 so
5 i 50 60
6 0 160 70
Repeat for the stress in the EXP case. The max stress in the EXP case is at node 78
o LoadCases C Hanger Data
CASE 5 (EXP) L5 L3-L4

Results
- -
Displacement
Restraint
Select From # | From Name | To #

9 75 76
10 76 77
11 77 78
12 0 78
!??
Next select the Nodal annotations. Annotate the two equipment connections as mentioned
previously.
Node 10 - PUMP A CONNECTION

Node 110 - VESSEL D CONNECTION
Perform a similar task for the elemental annotations, and annotate
Element 100 - 110 - LWN Flange as Nozzle
Finally enter the project attributes.
Attribute Name| Attribute Value

1 Project Name TRN
2 Project Number 001
3 Client Name TRAINING
4 Area T1
5 System TUTOR
6 Prepared by CJB

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Now we have completed the annotations, we can produce the drawings. Select Create Isometric
Drawing.
Create Isometric Drawing * Edit Stress Annotatio
[ Create Isometric Drawing
Select to Use Existing Style - as we have already created and configured our isometric style.
Select Drawing Style

O Use Default Style
Create New Style
@ Use Existing Style
OK Exit
PCF Files
ITUTORWITH LOOP.ori
Edit PCF
Browse to the Isometric ,Project and Stye directories as configured earlier
e\tcr x\i\\ nq "" " ' x
Select Isometric Directory

D \ISOGEN\ Browse ,. 1
Select Isometric Project
TRNPROJECT r Browse
Select Isometric Style

Stress Iso r Browse
j Create Drawing | | Exit
Once complete, click Create Drawing.

INTERGRAPH0
Tutor
After CAESAR II passes the information to ISOGEN, the data is processed and after a few seconds, a
drawing will be created.
Select the drawing created and click View.
Drawings
No o( Drawings 1
Drawing Path D \ISOGEN\TRNPROJECT\Stress lso \Drawings\
Status Message No errors
Drawings J \ Select All
TUTOR WITH LOOP.DWG
View View Message File Cancel
The annotations and attributes specified will be inserted into the resulting isometric.
The isometric could do with a little tidying up - the attributes are not quite correctly positioned. The
colours could also do with some improvement - perhaps to make the restraints/hangers stand out
more. All this can be done via l-Configure if required.
M
Lil
llnl;
tl
S
t s/s
[S<
mci
a ww TTTLE 2
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TTTU 3
LDCP t

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0
Cool H20 - FRP Piping
218
Cool HiO - FRP Piping
C00LH20
TEMPERATURE 50 C.
VALVE / FLANGE WEIGHTS' '
--
200 210
220 230
975G N
8900 N
PRESSURE 2 BAR
'
FLUID CODLING WATER
' m
290- 300 !! 00 N <61
320 - 330 1100 N
350 - 360
---
380 390
410 420
1100 N
1100 N
1100 N
d ep
,#
*
440 450 1100 N
& ;?
&
1?
It
4 IP'
A
*-
ALL MATERIAL WAVIN 55 *
BEND LAMINATE TYPE 3
STRAND MAT AND MULTI-
( CHOPPED
FILAMENT ROVING CONSTRUCTION)
CORROSION LAYER 1.5nn
ALL TEES ARE 'FABRICATED' TEES
ALL BENDS ARE LONG RADIUS MITERS
90* MITERS ARE 4 CUT - ALL OTHERS 2 CUT
This job consists of an FRP cooling water header, which decreases from 1800mm diameter to
1500mm diameter to 1200mm diameter to 1050 mm diameter as a succession of 750mm diameter
.
lines tap off it Modelling this job provides the opportunity for the user to explore the capabilities
that CAESAR II offers for analysing FRP pipe. Additionally static seismic loads will be applied to this
system, illustrating methods using uniform loads and load combinations.
Notes:
Tee types to be Type 1
Line stop (Axial Z restraint ) at node number 110

INTERGRAPH

Basics of Fibreglass Piping Analysis

Analysis of FRP materials is different to analysis of metallic materials, due to the orthotropic
properties of the FRP material.
Stress analysis of Fibre Reinforced Plastic components must be viewed on many levels. These levels,
or scales, have been called Micro-Mini-Macro levels, with analysis proceeding along the levels
according to the MMM principle.
Micro level analysis: Stress analysis on the Micro" level refers to the detailed evaluation of the
individual materials and boundary mechanisms comprising the composite material. In general, FRP
pipe is manufactured from laminates, which are constructed from elongated fibres of a commercial
grade of glass ( called E-glass), which are coated with a coupling agent or sizing prior to being
embedded in a thermosetting plastic material, typically epoxy or polyester resin.
Typically, on a micro level, the following failure modes are evaluated:
1) failure of the fibre

2 ) failure of the plastic matrix
3 ) failure of the fibre -matrix interface
Generally, the glass fibre is found to be much stronger in tension than is the matrix, so most tension
(along the axis of the fibre) is naturally taken by the fibre, rather than the matrix.
MATRIX
MICRO I r.vn GRP SAMPLE - SINGLE FIBRE EMBEDDED IN SQUARE

,
PKOriHiOr MATRIX
iHASS MUCH
Mini level analysis: Although feasible in concept, micro level analysis is not feasible in practice. This
is due to the uncertainty of the arrangement of the glass in the composite the thousands of fibres
which may be randomly distributed, semi-randomly oriented (although primarily in a parallel
pattern), and of randomly varying lengths. This condition indicates that a sample can truly be
evaluated only on a statistical basis, thus rendering detailed element analysis inappropriate.
For mini-level analysis, a laminate layer is considered to act as a continuous material, with material
properties and failure modes estimated by averaging them over the assumed cross-sectional
.
distribution The assumption regarding the distribution of the fibres can have a marked effect on the
determination of the material parameters; two of the most commonly postulated distributions are
the square and the hexagonal, with the latter generally considered to be a better representation of
randomly distributed fibres.

INTERGRAPH
Cool H 20 - FRP Piping
220
Use of these parameters permits the development of the homogenous material models which
facilitate the calculation of longitudinal and transverse stresses acting on a laminate layer. Typical
mini- level analysis shows that due to stress intensification and relative weakness of the matrix
relative to the glass fibres, laminate layers are typically very strong only in a single direction - i.e.,
the direction corresponding to the predominate alignment of the glass fibres.
n,
JU / / wu
MATRIX
X
STRESS INTENSIFICATION IN MATRIX cross SD. TION
m -Vi
1
i -7
D2 T\
AREAOhSlHKSS
IKTUNSIFICAHON
(
Macro level analysis: Where Mini level analysis provides the means of evaluation of individual
lamina layers, Macro level analysis provides the means of evaluating components made up of
multiple laminate layers. It is based upon the assumption that not only the composite behaves as a
continuum, but that the series of laminate layers acts as a homogenous material with properties
estimated based on the properties of the layer and the winding angle, and that finally, failure criteria
are functions of the level of equivalent stress.
PIPE FORCES AND

MOMENTS CAUSE
MACRO LEVEL
STRESSES... ...WHICH CAN BE
CONVERTED TO MICRO MACRO ip MICRO STHES >
LEVEL STRESES IN THE
CONVERSION
FIBER AND MATRIX
Since individual laminate layers are usually strong only in one direction, they are wound upon each
other at various angles to tailor the desired strength in various directions. Typically, for pipes, the
laminate layers would be arranged in such a way that their strength in the hoop direction is
approximately twice that in the axial direction.

INTERGRAPH
"
Total laminate properties may be estimated by summing the layer properties ( adjusted for winding
angle ) over all layers. For example:
ELAM \ | = (f )' (gl | kCik + E kCjk ) tk
Where:
Elam \ | = Longitudinal modulus of elasticity of laminate
tLAM = thickness of laminate
Ck , = transformation matrix orienting axes of layer k to longitudinal laminate
axis
Cjk = transformation matrix orienting axes of layer k to transverse laminate axis
tfc = thickness of laminate layer k
Once composite properties are determined, the component stiffness parameters may be
( determined as though it were made of homogenous material - i.e., based on component cross-
sectional and composite material properties, and interaction formulae for normal and shear stresses
can be developed.
7 -r 2 2
'sii 6 -
- ) + (-) =1
Theoretical
Test
5 -
4 -
T
3 -
2 -
1 -
0
0 2 3 4
CJ kgf mm "
COMBINED SI RESSES O AND TAT I AILURE: ARALDITE CY 232
(
INTERGRAPH

CAESAR s Orthotropic Model for Piping Systems

CAESAR ll's orthotropic material model is activated through the selection of Material 20 - FRP. The
orthotropic material model is indicated by the changing of two fields from their previous isotropic
values:
"Elastic Modulus (C) -> " Elastic Modulus/axial"

"Poisson's Ratio " -> "Ea/Eh *Vh/a".
These changes are necessary due to the fact that orthotropic models require more material
parameters than do isotropic. For example, there is no longer a single modulus of elasticity for the
material, but now two - axial and hoop. There is no longer a single Poisson's ratio, but again two
Vh/a (Poisson' s ratio relating strain in the axial direction due to stress-induced strain in the hoop
direction) and Va/h ( Poisson' s ratio relating strain in the hoop direction due to stress-induced strain
in the axial direction). Also, unlike with isotropic materials, the shear modulus does not follow the
relationship G = 1/ E (1-V) as for metals, so that value must be explicitly input as well.
In order to minimize input, a few of these parameters can be combined, due to their use in the
program. Generally, the only time that the modulus of elasticity in the hoop direction, or the
Poisson's ratios are used during flexibility analysis is when calculating piping elongation due to
pressure (note that the modulus of elasticity in the hoop direction is used when determining certain
stress allowables for the BS 7159 code) :
Where:
dx = extension of piping element due to pressure
crx = longitudinal pressure stress in the piping element
Ea = Modulus of elasticity in the axial direction
~ Poisson s ratio relating strain in the axial direction due to stress induced strain in
Vh / a
the hoop direction
Ohoop = Hoop pressure stress in the piping element
Eh = Modulus of elasticity in the hoop direction
L = Length of piping element
This equation can be rearranged, to require only a single new parameter as:
( )
Note that in theory, the single parameter jr x V / a is identical to Va/h.
(
V
INTERGRAPH
*
Requirements of the ISO 14692 Code

In light of the isotropic nature of fiberglass reinforced plastic pipe, where hoop and axial strengths
are distinct, stress evaluation in ISO 14692 utilizes an idealized envelope of combinations of axial and
hoop stresses which cause the equivalent stress to reach failure. This curve represents the plot of:
{ * 1 (
\
g/l
P
all )
[ axahoop
< io
' Gx- all' hoop c-all hoop all .
Where:
0x - au = Allowable stress, axial
hoop- aii = Allowable stress, hoop
These terms are expressed in the ISO short term failure envelope:
/ short term failure envelope

co
CO
B
CO
BX
sa(2:1)
< / (1:1)
2: 1 )
asa(0:1)
Hoop Stress sh(2:i )
ISO SHORTTERM FAILURE ENVELOPE
The ( 2:1) line indicates points where the hoop stress is twice the axial stress. This stress state occurs
.
in the wall of a pressurized, closed cylinder The shortterm axial strength, aM( 2 :l), and short term
hoop strength, osh( 2:l), occur where this (2:1) line intersects the failure envelope. By definition,
aSh(2:l)=2 * oH(2:l). A third strength is illustrated here - 0 10:1) - this is the axial strength of the pipe
*
in the absence of pressure.
But there are several factors which reduce this short term strength in setting allowable (hoop and
axial) pipe stress:
Reduced long term strength of the component [fscale]

A design safety factor ( based on load type) [f2]
Accommodation of specific load conditions (reduced strength associated with
temperature, chemical attack, and fatigue) [Al, A2, A3 ]

INTERGRAPH
CADWorxe
& Analysis Solutions
This short term failure ellipse can be represented by a fully measured envelope shown below:
design short, ideal

on9 deal
factored design ' '
ISO FULLY MEASURED ENVELOP
The line set intersecting the short term failure ellipse is a straight line representation of that ellipse -
labelled short, ideal . The manufacturer can establish osh(2:l) from burst tests (and half of that is
asa ( 2:l)) and can establish oM(0:l) from tension tests. The next smaller line set, labelled long, ideal
reflects the long term strength of the pipe. This is the material limits usually provided by the
manufacturer. Using long term pressure testing, the manufacturer can project the end of life
strength of their components. The ISO Code reduces this material data by a system factor of safety.
.
This is the third line set, labelled design here The limits used for piping evaluation are shown in
the smallest line set, factored design . Factored design limits account for those operating
conditions that reduce long term strength of the piping material.
Note also the (1:1) line in the figure above. This line represents the stress condition where the axial
.
stress equals the hoop stress While having no engineering design significance, this line produces a
point on the failure ellipse where the axial limit will drop below oM( 2:l). The manufacturer may
.
provide o fl:!) (or the equal osh(l:l)) If not the following simplification may be necessary:
sa(2:1)
Hoop Stress sh : )
ISO SlMPLIHfcD ENVhLOIJfc
(
INTERGRAPH
*
225
The dotted line set shows the simplified short term strength. This envelope would then be reduced
to a similar factored ( long term) design envelope described above. This curve is also used in the
UKOOA Code.
ISO 14692 Annex D provides equations for effective hoop and axial stresses in piping component.
These effective stresses combine structural loads (due to weight, thermal strain, etc.) with pressure.
Safe design is assumed if both the hoop and axial stresses lie within the factored design boundaries.
CAESAR II analysis will evaluate both hoop and axial stress. The effective hoop stress must be less
than the factored design limit for hoop stress. The axial term will also be evaluated but, here, the
allowed axial stress is a function of the hoop stress. CAESAR II will report the stress term (hoop or
axial) that produces the largest stress/limit ratio .
The strength envelopes above are for straight pipe. Other piping components such as tees, bends
and joints do not have fully developed strength envelopes. Instead, manufacturers establish a
qualified stress, oqs, for these components.
Mfitting = (2 X Mfitting
Where:
D = mean diameter of matching pipe
tr = reinforced pipe thickness of the matching pipe
pq = Qualified pressure of the fitting
This is a combination of equations ( 6 ) and (7) of the Code.
Qualified stress serves as the long term design hoop assigned to pipe. This qualified stress will be
adjusted by the same terms as pipe to develop a long term hoop design stress. The axial limit is
established through the biaxial stress ratio, r.
For pipe, r = 2 ( *f0:1) I (Equation (12) of the Code). The ISO Code assigns values for r for non-pipe
\ ffsh(2:l) /
.
components in Table 4 Given r and the qualified stress, CAESAR II will calculate 053 (0:1) for the
.
component CAESAR II requires qualified stress and biaxial stress ratio for bends and joints. Tees
have r=lso only require a qualified stress. The stress envelope for a non-pipe component is a simple
rectangle bounded by a factored design hoop (or qualified) stress and an axial stress equal to r times
that hoop limit. Note that, for some piping components with relatively large axial strength, r can go
as large as 2 indicating that the component is just as strong axially as it is in hoop for any hoop
stress.
(
INTERGRAPH

Allowable Stress Data for this Model

As shown on the isometric, the material for this model is Wavin 55 material.
Pipe Data:
The value for longterm hoop strength (shown as hl( 2:l) in CAESAR II) may be obtained from vendor
data. In the case of the Wavin 55 material, it is available from the graph of the combined stress
failure envelope, as shown below. Note that the axes have been switched (axial stress on the
horizontal axis) on this graph relative to the traditional ISO envelope format, so the desired 2:1
position is now identified as R = 0.5. Likewise, the values in this graph include the service factor f 2,
which can be eliminated by dividing the values on the outer curve by 0.67. This gives a fl x LTHS
value of 125 N/mm2. An alternative means of getting this value is to find the value given by the
vendor for the long term Hydrostatic Design Basis; again, for this case 125 MPa. The long term axial
stress at maximum hoop stress, al( 2:l), is, by definition, half of hl( 2:l). The axial tension-only long
term strength is shown on the chart below as ( 41 MPa/0.67 ).
Piprs, WINDING ANGLE OJ = 55

-
Pipes, u 65"
Axial stroM
340 Hoop strops
320
900
THS *
* /**?
5 10 IS 20 25 30 35 4Q \ 45
Axial stress (N/mml)=

i
=C> | s
- -
Afawahle stresses lor hydrostatic loading, sendee (design) (actor 0.5, Seq 19.3 N/mm*
. -
AJkxwabto stresses for combined loading, sorvtoa (design) lector - 0.67 Saq(max) 24.5 N/mm>
Allowable atresses (or combined loading In combination with shear sties , Seq(mas) 24.5 N/mm>
* -
(
INTERGRAPH
0
HYDROSTATIC PROPCRTIES
Winding angle (o)

Proparty
Test method 55* 63* 73*
Bt-axlat (R = 0.5)
Ultimate hoop stress

(rupture)
650 500 - NAnm*

(weeping)
ASTM D 1599 250 200 - Wmrrf
Ultimate Elastic Wall Stress

(UEWS)
Future Pips Industries 160 140 - Wmm>
Hydrostatic Design Basis

HDB (50 years)
ASTM D 2992 B
() 100 - NAnm*
Hydrostatic Design Stress

HDS (50 years)
ASTM D 2992 B ' 63 so Nlmnf
Uniaxial: (R = 0.25)
Ultimata hoop stress - 1000 800 NAnm*

(rupture)

ASTM D 1599
- 450 370 NAnm*
(weeping)
Hydrostatic Design Basis

ASTM D 2992 B - 200 160 NAnm*
HDB (50 years)
Hydrostatic Design Stress

ASTM D 2992 B' - 100 80 NAnm
HDS (GO years)
Joint & Fitting Data:
Tees, bends and joints reference Qualified Stress instead of the pipe term hl( 2:l). For this example,
these components have a lower pressure rating than the matching pipe. The Qualified Stress ( Qs)
will also be set to 75 MPa. The axial stress limit for tees is constant but bends and joints may have a
varying axial stress limit measures by r, the ratio of two times al(0:l) divided by hl( 2:l). For this
model, r is set to 2 for joints and 1.0 for bends. Bends also reference the hoop modulus of elasticity
which is entered here as the Eh/Ea ratio of 1.7
Other factors:
A1- factor for temperature

A 2 - factor for chemical resistance
A 3 - factor for cyclic service
System Design Factor - this is a CAESAR II term that is combined with the CAESAR II Occasional
Load Factor (which is set or adjusted in the Load Case Options) to produce the part factor for
loading .
(
INTERGRAPH
'
228
Configuration Options for FRP Piping:

In this example, the material has the properties of Wavin 55 o winding FRP pipe. These parameters
are:
Ea = 12,000MPa
Eh = 20,400 MPa (Eh / Ea = 1.7)
Eh / Ea Vh / a = 0.38
Density = 1849 kg / m3
6
CTE = 206 x 10 mm / mm / C
Shear Modulus = 11,496 MPa
Bend Laminate Type = Chopped Strand mat with multi - filament roving construction
CAESAR ll's material database is not currently configured for orthotropic materials such as FRP.
Therefore, CAESAR ll's orthotropic model must be triggered through use of Material 20 (FRP ), with
the material parameters entered explicitly. These parameters include:
Axial Modulus of Elasticity ( Ea ) ( entered on spread sheet)

The Ratio (Ea / Eh )Vh/ a ( entered on spread sheet )
Pipe Density ( entered on spread sheet )
Coefficient of Thermal Expansion ( entered on Special Execution Parameters)
Ratio of Shear Modulus (G ) to Axial Modulus ( Ea ) ( entered on Special Execution Parameters )
FRP Bend Laminate Type ( entered on Special Execution Parameters )
This may become tedious, especially if the same type of FRP material is used frequently. In this case,
the appropriate material parameters may be entered in the CAESAR II Configure/Setup, to be used
automatically whenever Material 20 is used.
[
CAESAR II Configuration Editor
i0 Q Reset All Data Directory : D:\Tralning\CAESAR n\ -

Material Properties
Axial Modulus of Elasticity 11999996.143
0 Configuration Axial Strain : Hoop Stress (Ea/Eh*Vh/a) 2.620
Computational Control FRP Alpha 20.002
Database Definitions ia;isiotofr> - - 1850.002
FRP Properties FRP Laminate Type CSM and Multi- filament
Geometry Directives WAVIN55.FRP
FRP Property Data File
Graphics Settings 0.958
Ratio Shear Modulus : Elastic Modulus
Miscellaneous Options
SIFs and Stresses
B Settings
BS 7159 Pressure Stiffening _
Design Strain
Exclude F2 from UKOOA bending stress False
Use FRP Flexibilities True
Use FRP Sif True
(
INTERGRAPH
0
CoolH 20 - FRP Piping
These parameters are entered using the FRP PROPERTIES group in of Configure/Setup. The
configuration items are described below :
.
Axial Modulus of Elasticity: Self-explanatory; can be read from an FRP file
Axial Strain : Hoop Stress ( Ea/Eh * Vh/a ): Ratio of the FRP axial modulus of elasticity to the hoop
modulus of elasticity, all multiplied by Poisson's ratio for strain in longitudinal direction due to
stress-induced strain in circumferential direction; can be read from an FRP file.
FRP Alpha (x E-06): The coefficient of thermal expansion, length/length/degree, multiplied by

1,000,000; can be read from an FRP file.
FRP Density: Self-explanatory; can be read from an FRP file.

FRP Laminate Type: This item is considered when calculating SIFs and Flexibility Factors of bends
.
under the BS 7159 and UKOOA codes Choices include:
Type 1- All chopped strand mat (CSM) construction with an internal and an external surface
tissue reinforced layer.
Type 2 - Chopped strand mat ( CSM) and woven roving ( WR ) construction with an internal
and an external surface tissue reinforced layer.
Type 3 - Chopped strand mat ( CSM) and multi-filament roving construction with an internal
and an external surface tissue reinforced layer.
FRP Property Data File: Selecting an FRP type from one of the ones listed reads in much of the
associated material data.
Ratio Shear Mod : Elastic Mod: Ratio of the FRP shear modulus to the axial modulus of elasticity; can
be read from an FRP file.
The remaining settings are used with the other FRP codes BS 7159 and UKOOA and are unused for
ISO 14962. Their uses are discussed in the help file and are displayed on pressing FI while on the
field.

INTERGRAPH
"
)
Model the system

When modelling using the orthotropic material, the very first thing that must be done, before even
creating a new file, is to enter the material properties in the configuration file (remember this can be
done by selecting an FRP data file). The once material 20 is selected within the job, these properties
.
will be used Any changes made to the FRP properties in the configuration file will only take effect
when a new job is created.
On the CAESAR II main window, select Tools > Configure/Setup
9
Tools
D 9 ra <$ M~ <fc Configure/Setup
= Make Units files
Select the RP properties node and specify the properties of the FRP. This FRP is Wavin55 as
mentioned previously. Select this FRP property data file.
3 Material Properties
Axial Modulus of Elasticity 12000051.300
0 Configuration Axial Strain : Hoop Stress (Ea/Eh*Vh/e) 2.620
Computational Control
FRP Alpha 20.002
Database Definitions
FRP Density 1849.024
FRP Properties
FRP Laminate Type CSM and Multi- filament
Geometry Directives
Graphics Settings
1 FRP PropertyData File WAVIN55.FRP
Ratio Shear Modulus : Elastic Modulus AMRN55-21.FRP
Miscellaneous Options 3 Settings AMRN55-93 FRP
SIFs and Stresses AMRN7KM.FRP
BS 7159 Pressure Stiffening
Exclude F2 from UKOOA bending stress AMRNPSX.FRP
Use FRP Flexibilities CONLEY.FRP
Use FRP Sif SMITHGR 150 FRP
SMITHGR200 FRP
SMITHGR 75.FRP
IjWftViijlSSiFRP
WAVIN63 FRP
WAVIN73.FRP
k
Confirm the choice
Do you want to read in the material properties from this frp pipe file?
Yes No
The FRP parameters will update to those set in the FRP data file.
Whilst in the configuration file, also specify a default friction coefficient of 0.15 to represent plastic
on steel/concrete.
MUU I UICIUIIVC
(3 Input Spreadsheet Defaults

Alpha Tolerance 0.050
J 0.150
1 IlnJll 1

INTERGRAPH
CADWorx 0 & Analysis Solutions
Once these FRP parameters have been set, only then can the job file be created. Create a new job
file called CoolH 20.
New Job Name Specification
Enter the name for the NEW job file

CoolH20
O Piping Input Structural Input

piping files, even if they are to be combined for analysis
Enter the data directoiy

D: \Training\CAESAR n g
OK Help Cancel
Create the first element, 10 to 20. Note that this pipe is non-standard 1800mm diameter and also
has non-standard 46mm wall thickness.
The 1.5mm Corrosion layer should also be entered here. This layer will always be used in the weight
and thermal force calculations, but excluded from the pipe strength calculations.

From: 10
Name
To; 20
>>
DX
DY:
DZ 6700 000 mm
Offsets

Diameter: 1800 0000
Wt/ Sch 46 0000
Select the material number 20 - FRP.
Material (20JFRP (FIBER REIN PLASTIC -

2 Allowable Stress

Elastic Modulus / axial 1.2000E *007
Elastic Modulus (H1)

Elastic Modulus (H2):
Elastic Modulus (H3)'
Ea/Eh*Vh/a. 0.3800

INTERGRAPH
0
Upon selection of the material, the labels on the material properties change. Elastic Modulus (C)
becomes Elastic Modulus/axial and Poisson's Ratio becomes Ea/Eh * Vh/a.
The values will be brought in from the FRP data file and will be as described above (as we chose the
Wavin55 FRP data file ).
Also check the Special execution parameters for further FRP data. Again this should match the
correct data coming from the FRP data file.
uai7 jniua:< jiiirTu:fcTBirirjrafc .. <
Print Forces on Rigids and Expansion Joints: v

Print Alphas and Pipe Properties
Activate Bourdon Effects (for this job): None v
Branch Error and Coordinate Prompts: None * (

Thermal Bowing DeltaTemperature: 0.000
Liberal Stress Allowable (lor this job) 13
Uniform load in G' s
Amhipnt tpmnprfllurp ffnrthis inhV 21 114
-
FRP Coef. of Thermal Expansion (x 1.000.000) (len/ len/ ): 20000
FRP Ratio of Shear Modulus /Emod Axial: 0.958

FRP Laminate Type: 3 f
V
- 4-AXIS vertical a
Enter the temperature and pressure (50C and 2 bars).
We must now also select the design code. Currently the code is the default - B31.3. Change this to
ISO 14692. Now we must enter the stress envelope for the FRP material. The entries are as
described previously. Recall the graph:
(
INTERGRAPH
233
Plpei, 0 66 -- _
R - Axial atreaa
Hoop stress
f , X LTHS = 8Y / o.b'f
= &
=
*18 *.!** *
} 11S
'
psi
t - 0 (Hnr.O
t 5
10
too -TjSq
- 19J3 fi/rrvn t fS
o to ts 20 25
m
Axial stress (N/mm*) c
*0 \ 45
(as mentioned before, the axes have been switched, so the 2:1position is now identified by R = 0.5),
and also recall that mentioned previously the values on the graph include service factor f 2, 0.67. This
factor also needs removing (i.e. divide all values by 0.67). the 0.67 value will be entered as the
system design factor .
As shown in the graph, the reading for the hoop stress is 84 N/mm 2. Therefore the hl(2:l) value is:
84
hlfz DJ =
lz -1 0.67
= 125 MPa
By definition, long term axial stress at maximum hoop stress, al(2:l), is half of hl( 2:l). Therefore:
a (2:l)
(2:1) _ 125 .
bl SMPa
2 2
The axial tension-only long term strength is shown on the chart above as 41 MPa. Therefore
ai(0:i) = = 61.2 MPa
The joint and fitting data is also discussed above. The Qualified stress Qs will be set to 75 MPa and
.
for bends r = 1.0 and for tees r = 2 Bends also reference the hoop modulus of elasticity which is
entered here as the Eh/ Ea ratio of 1.7.

(
INTERGRAPH
*
234
Al, A 2, & A3 bring in environmental effects to reduce the design stress to the factored design stress.
Thermal Factor ( k ) is the mean temperature multiplier , a factor by which the difference in
temperature between the fluid the environment is to be multiplied (since FRP has natural insulating
.
qualities) For liquids, the Code dictates a K value of 0.85; use 0.80 for vapour.
Code IS014692
Failure Envelope for Plain Pipe
al(0:1) 61.200 al(2 1) 62 500
=1(1:1) hl(2 1) : 125.000

hl(1:1)
Failure Envelope for Joints / Fittings

Joints Bends
Qs: 75.000 Qs 75.000
r 2.000 r 1.000
Tees (r *1 0) Eh/Ea 1.700
Qs 75.000 Hand Lay
Partial Factors for Temperature (Al)

1: 1.000 A 7.
2: 5: 8
3: 6 9.
Other Partial Factors
Chemical Resistance (A2) 1 000

Cyclic Service (A3) 1 000
System Design Factor 0 670
Thermal Factor (k) 0.850
Note that we have not entered al(l:l) or hl(l:l) therefore the simplified envelope will be used.
Complete the first element by adding an anchor at node 10 and continue into the bend.
The bend is a mitred bend and has 2 mitre points. Note that the ISO Code ignores the number of
mitres when calculating the bend SIF and flexibility factor.
Radius Long
Type
Angle 1 M Node 1: 19
Angle 2 0.000 I Node 2 I0
Angle 3 | Node 3
Miter Points 2
Fitting Thk:
K- f actor
l
INTERGRAPH
*
235
In addition, there is also a +Y restraint on the start of the bend ( node 18). Notice the friction factor
is included automatically when adding the restraint.
Node iE CNode
Type ANC Gap
Stif Mu
Node 18 CNode
Type: +Y
- Gap
Slil Mu 0.150
Continue to the next element.

From: 20
To 30
J
DX. I
DY '1825 000 mm
DZ 5800 000 mm
The model so far should look like the one below:
Continue and complete the model. Note the following points:
The branch connection at node 40 (as well as all other branches) is a tee (SIF type 1).
Node 40 (along with nodes 60, 100, 120, 160, 180, 190, and 250) is supported by a +Y
(weight only) support ( with friction coefficient of 0.15).
The restraint at node 50 (as well as those at nodes 90, 110, 150, and 170) is combination
guide and +Y ( weight only) restraint (with friction coefficient of 0.15).
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*
Element 70-80 is a reducer (conical section). It can be modelled as such with the exiting
diameter and thickness set to 1500mm and 38mm.
There is a Z restraint located at node 110
.
Element 40-280 is a branch off of the 1800 mm line Its diameter and thickness should be changed to
.
750 mm and 25 mm, respectively (Offsets should be considered here as the actual flexible length of
straight pipe [ before the bend] - 3600 mm - is much smaller than the modelled length - 4500 mm -
and therefore much stiffen However, for this layout the effect is minimal [about 5% in terms of
.
stress] and excluded for simplicity ) The bend at node 280 has 4 mitre points.
After modelling the branch through node 300, that branch can be duplicated via the list processor 5
times ( with the node increment set to 30, 60, 90, etc.). It is also necessary to change the branch
intersection nodes to 60 (from 70), 120 (from 130), and 180 (from 190).
The completed model should look as below. Remember there is also a Z restraint located at node
110 ( which will be inside the pipe).
Error Check the model
.Message
. T
Type
Message
Number
Element/
Node Number
Message Text
WARNING 505E 10-20 al( l: l) and hi( 1:1) on element 10 to 20
are not specified . The simplified envelope will be used .
A warning relating to the fact that al(l:l) and hl(l:l) were not entered and so the simplified
envelope will be used is shown, and that the reducer Alpha was not entered so CAESAR II has
calculated this value.
Accept these warnings and access the load case editor.

c
INTERGRAPH

Load Case Sell p

ISO 14692 evaluates both hoop stress and axial stress in the installed and operating conditions and
.
also for any short duration (occasional) loads The type of load will set the part factor, f2, used to set
the design stress limits. The System Design Factor specified in the input is multiplied by the CAESAR
II Occasional Load Factor in the Load Case Options tab to produce this f2. f 2 = (System Design
Factor) * ( Occasional Load Factor). The Code provides values for f 2 in Table 3. Remember that the
System Design Factor in the CAESAR II input is set to 0.67.
Q a a &
Load Case Editor Load Casa Options [ Wind Loads j Wave Loads
Loads Defined in Input Load Cases | Stress Type Recommend

-
W Weighl L1 W+T1+P1 OPE
-
T1 Thermal Cose #1 L2 W+P1 SUS
-
PI Pressure Cese #1 L3 -
L1 L2 EXP Load Cydes
WW - Water Riled Weighl
WNC - Weighl no contents Import Load Cases
i-r Static Analysis - [D:\TRAINING\CAESAR II\COOLH20]

; File Edit
IQS tt
Elbow Elbow Flange

Elastic Stiffening Friction Occ Load
Load Coso Namo Stiffening Analysis
Modulus Elastic Multiplier Factor
Pressure omperature
Modulus
L1 OPERATING CASE CONDITION 1 EC PMax EC 1 000 : 1 2390 lone
12
L3
SUSTAINED CASE CONDITION 1
EXPANSION CASE CONDITION 1
EC PMax
PMax
EC
EC
1 000
v
_
1 0000 Icne
J lone
Review Results
ISO 14692 Annex D provides a method for converting torsion and bending moments into hoop and
axial stress terms. These stresses, summed with their pressure counterparts, produce effective hoop
.
stress and effective axial stress Terms common to B31 piping - flexibility factor and stress
intensification factor - are used here too. Stress evaluation will first compare effective hoop stress
to the factored design hoop stress. If this check fails, the hoop stress is reported, otherwise, CAESAR
II will continue with the axial check. The effective hoop stress is used with the design envelope to
pick up the factored design axial stress. The effective axial stress is then compared to the factored
design axial stress. If this check fails, the axial stress is reported, otherwise CAESAR II will print the
cause of the largest (stress/limit) ratio - either hoop or axial.
Running this analysis shows that this system stresses are satisfactory Note the changing allowable.
stress from node to node. CAESAR II prints a different allowable depending upon which stress
calculation controls - Hoop or Axial.

INTERGRAPH

238
Solving Expansion Problems

The philosophy behind solving expansion problems in a fiberglass piping application is different from
that in a steel piping application. For steel piping, the preferred hierarchy for solving such a problem
is 1) adding flexibility through loops and bends, 2) using expansion joints, and 3 ) using restraints to
.
re-direct growth to areas where it can be better handled For fiberglass applications, due to the
relatively low modulus of elasticity of fiberglass, the lack of significant flexibility provided by FRP
bends, and the potential problems involved in the joining of FRP sections, the hierarchy is exactly the
opposite. The preferred method is to use axial restraint to force the thermal expansion into
compression (in this case, the line must be adequately guided); the next preference is to use
expansion joints; and the last resort is to use expansion loops.
Static Seismic Using the ASCE 7 - 05 :

This cooling water system is located in a seismically active region, so it must also be designed to
.
withstand earthquake loads For this analysis, the ASCE 7 Minimum Design Loads for Buildings and
Other Structures, 2005 Edition is in effect. We will assume that this installation is located in Site Class
D (Stiff soil profile), near Los Angeles, California. ( For Site Class Definitions, refer to Table 11.4-1.)
The structure in which this system is operating has an average roof height of 12m. Section 13.3.2
.
discusses Seismic Relative Displacements to which piping must be designed It states The effects of
seismic relative displacements shall be considered in combination with displacements caused by
other loads as appropriate. - meaning that they shall be treated as secondary loads, rather than
"primary" loads.
Inertial Loads
Section 1621.1.4 defines a horizontal seismic acceleration factor to be applied uniformly throughout
the structural mass. This acceleration factor, aH, is defined as:
0.4apSD5
aH
lv
( ?)
But: - S 1.6 Sp$ lp and 0.3 Sp lp
Where:
QH
I
ap = Component amplification factor, from Table 13.6-1
= 2.5 for piping
SDS .
= Design elastic response acceleration at short period, from Section 11.4 4
Rp = Component response modification factor, from Table 13.6-1. Use 4.5 for pipes not
in accordance with B31, with bonded joints or use 12 for welded, steel B31 pipe .
= 4.5
lp = Component importance factor, from Section 13.1.3 (1.5 for life-safety

components, hazardous material containing, or piping is in a Category IV structure
(essential facility); 1.0 for all others).
(
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* ..
PAmJtfnrv &
CADWorx Analysis Solutions
0. Anolocie Cr li Hone
= 1.0
z = Height in structure at point of attachment. Here, use the average of elevation of all
8 connections
= 6m
h = Average roof height of structure

= 12m
Section 13.3.1 states that a vertical acceleration be considered as well. This acceleration factor, av, is
defined as 20% of the Design elastic response acceleration at short period, or:
Ciy = 0.2 S05
Determine SD5:
From section 11.4.4
$DS - $MS
Where
SMS = Maximum considered earthquake spectral response accelerations for short period
adjusted for site class effects
And from section 11.4. 3
SMS ~
FaSs
Where:
Fa = Site Coefficient defined in Table 11.4-1

= 1.0
Ss = Mapped spectral accelerations for short periods, from Section 11.4.1

= 1.552 g ( see below )
Maps of spectral acceleration are available from several sources ( ASCE, IBC, NEHRP, and FEMA ). Data
is also available on-line at http: // earthauake. usgs . gov/hazards / using the Java Ground Motion
Parameter Calculator (http:// earthQuake . uses . e0 v / hazards / designmap 5 / iavacalc. php). The location
of this piping system on the coast near Los Angeles is 33.9083 latitude and -118.41045 longitude.
Below is a screen capture from the USGS software. Ss for the location of interest is shown;
SS=1.552g.

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240
Seismic Heard Cunts and Unrfonr Heart Rgporw

.
File Help
Select Analysis Option jASCE 7, Standard , minimum design toads for buitriinfls and other structures T| 1 Description
Region and OataSet Selection
| ContiItnisiout o# State*
Output for All Calculations
Centereineua 4 i States
2005 A3CE 7 Standard

latitude 33.99!]
Data Edition
Icngitttde
-- US . 41945009000001
( spectral Resptase Atselerarlcns Ss and SI
12005 ASC 7 Sttndird 3 Ss aad SI Happed Spectral Acceleration Values
Site Class 9 - r* 1.0 , FV 1.0 -
Cata are based cn a 0.01 deg grid spicing
LoVton |Zip Code| Batch Frfo! reeled Sa
latitude (Degrees ): - Longitude lDegrees ): - (sec)
0.2
(?)
1. S 52 CSs, Site Class Bl
11 KU IB 41045 | 1.0 0.82! ( SI , Site Class B|
( 24.70, 50.00 ) -
( 125.00 , 65.00 )
Grot
Calculate SJfcSl Calculate SM & SO Values

"
Response Spectra [ View Maps ] | dear Data
C
|
stop Spectrum
Design Spectrum
Site Modified Spectrum
View Spectra
|
D ZUSGS
schnco fv a dunging world
Therefore:
SMS = FaSs = 1.0 x 1.5520 = 1.5525

2 2
SDS = = 1 5525 = 1 0355
So the appropriate seismic acceleration is:
aH
0.4 dpSDS
Rp
lv
{ D
0.4 x 2.5 x 1.035 2 x 20 \
4. 5 40 /
TU
aH 0.4605
Checking the limits on aH:
an 1.6 SDsIp aH > 0.3 Spslp
aH 1.6 x I . I 85 x 1.0 a 0.3 x I . I85 x 1.0
aH 1.883 5 v' aH 0.353g
dy 0.2S[JS
av = 0.2 x 1.035 = 0.2075

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CADWorxs
& Analysis Solutions
Seismic load adjustment: The building codes are based on strength design where components (such
as reinforced concrete structures) are evaluated on their load -carrying capacity rather than stress.
Piping codes are based on allowable stress design and, while the calculated seismic load provides a
good estimate of the internal loads and deflections of the piping system, these seismic loads over
. .
predict the resulting stress used here Section 13.1 7 states The earthquake loads determined in
.
accordance with Section 13.3 1 shall be multiplied by a factor of 0.7.
Therefore the adjusted seismic loads for allowable stress design are:
aH = 0.7 x 0.460 = 0.322g

av = 0.7 x 0.207g = 0.145 g
Relative Seismic Displacements:
Section 1621.1.5 discusses the means of addressing relative displacements due to story drift - this
should be calculated via a structural analysis of the enclosing building. Assume this analysis yields
the following displacements ( with attachment points near building columns, no vertical drift is
included):
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*
242
Node Function Approx Elev (m) X-Disp ( mm) Z -Disp (mm)

10 Anchor 4.6 26 9
18 +Y 4.6 26 9
40 +Y 2.8 16 5
50 X, +Y 2.8 16 5
60 +Y 2.8 16 5
90 X, +Y 2.8 16 5
100 +Y 2.8 16 5
110 X, +Y, Z 2.8 16 5
120 +Y 2.8 16 5
150 X, +Y 2.8 16 5
160 +Y 2.8 16 5
170 X, +Y 2.8 16 5
180 +Y 2.8 16 5
190 +Y 2.8 16 5
240 +Y 28 16 5
270 Anchor 0 0 0
300 Anchor 7.3 42 14
330 Anchor 7.3 42 14
360 Anchor 7.3 42 14
390 Anchor 7.3 42 14
420 Anchor 7.3 42 14
450 Anchor 7.3 42 14
Note: Displacements need only be placed on +Y supports if friction loads are considered to be
significant.

INTERGRAPH
243
Seismic Data Input

We have already calculated the Seismic data and could build uniform loads to model the load in the
X Y and Z directions from what we have just calculated. Alternatively, CAESAR II includes a static
seismic wizard which can be used to perform all the calculations automatically, and build the
uniform loads and incorporate into the model.
We will use the static seismic wizard, and see that the values match up to our hand calculations.
The Static Seismic Wizard is available from the same toolbar as the Loop design wizard used
previously.
. A,
!
*a T
~
Jj- Static Seismic Wizardjj
1
The static seismic wizard provides input for the various data we have discussed previously.
Recall the following values:
ap = Component amplification factor, from Table 13.6-1

= 2.5 for piping
Rp .
= Component response modification factor, from Table 13.6-1 Use 4.5 for pipes not
in accordance with B31, with bonded joints or use 12 for welded, steel B31 pipe .
= 4.5
Ip .
= Component importance factor, from Section 13.1 3 (1.5 for life-safety
components, hazardous material containing, or piping is in a Category IV structure
(essential facility); 1.0 for all others).
= 1.0
z .
= Height in structure at point of attachment Here, use the average of elevation of all
8 connections
= 6m
h = Average roof height of structure
= 12m
In addition, we have the Ss value obtained from the USGS utility = 1.552
Input the data into the Seismic Wizard
Seismic Wizard f
*
Seismic Design Code : ASCE 7- 05/IBC 200
'
Importance Factor 1: 1 |
Response Factor R : 4.5
. . .
Max Mapped Res Acc Ss : 1.552 g'<
Site Class : 0
Component Elevation ratio z/h : 0.5
Component Amplification Factor ap : 2.5

INTERGRAPH
*
244
On clicking OK, the values will be calculated for aK and av as we have done manually above. These
will be included as Uniform Loads. (The uniform load will act on following elments until removed or
etto zero).
Expansion Joint
Vector 1 Vector 2 Vector 3
v] Restraints ED Displacements 0322 0.000 0 000
Hangers Range Checks 0.000 0145 0000
Nozzle Rex Nozzle Lmt Check
0.000 0.000 0.322
Fnrro < / Mnmpnlj
v Uniform Loads
, m G's 6 in G's o in G's
Wind / Wave

in F /L in F/ L in F/L Jj
Note that the Uniform loads are also in g's.
Next we also need to apply the displacements due to Storey-shift as detailed previously These .
displacements can be modeled as vector D1(for X-direction) and vector D3 ( for Z-direction). They
should be applied to CNODEs attached to the restraints ( increment each restraint by 1000). To save
inputting effort, all restraints at a common level could be connected to a single CNODE. In this case,
displacements need only be entered at three locations.
Add the displacements only at nodes 10, 40 and 300.
T|
Node 10
|Node 1 , 1010
Vector 1 | Vector 2 [ Vector 31
/ector
DX 26 0000 0 0000
DY 0 0000 0 0000
DZ 0 0000 9 0000
RX 0 UUIKJ j. x O.UUOVT
RY 0 0000 0 0000
RZ 0 0000 0 0000
i 0 \
Node 40
f Node 1 fl
_L ""Vector 11 Vector 21 Vector 3 'Yector
DX 16 0000 0 0000
DY 0 0000 0 0000 L_
DZ 0 0000 5 0000 1
RX 0 0000 0 0000
RY 0 0000 0 0000 \
RZ 0 0000 0 0000 i

INTERGRAPH
0
245
Node 300 r Node 1: 1300
( Vector 1 Vector 2 Vector fj\/iector

DX 42 0000 0 0000
DY 0 0000 0 0000
DZ 0 0000 14 0000
RX 0 0000 0 0000
RY 0 0000 0 0000 I
RZ 0 0000 0 0000
We now have the restraints defined, but currently they are defined as displacements at nodes 1010,
1040 and 1300. These nodes do not exist in the model.
We will use these node numbers as cNodes and connect all the restraints to the relevant
.
displacement at the correct elevation All restraint nodes at 4.6 m elevation must be connected via
Cnode to displacement node 1010. (These are nodes 10 and 18).
Node: 10 CNode 1010
Type: ANC Gap
Stif: Mu:
Node: 18 CNode 1010
Type: Y Gap
Stif: Mu 0150
Similarly, restraint nodes at 2.8 m must connect to 1040 ( Nodes 40 - 240) and nodes at 7.3m
elevation must be connected to 1300 (nodes 300 - 450) .
This is easier to perform usi ng the Restraint List view.
(
INTERGRAPH
Restraints
TO RESTR STIFFNESS
GAP or MU
FROM
NODE NODE NODE TYPE KHJmm . LENGTH
mm . or
FI (N. )
CNODE
9 40 50 50 +Y 0 1500 1040
10 50 50 Guide 0 1500 1040
11
112 50
13 BO 90 90 +Y 0 1500 1040
14 90 90 Guide 0 1500 1040
15 90
16 so
17 90 100 100 + Y 0 1500 1040
118
19
20
21 100 110 110 + Y 0 1500 1040
22 110 Guide 0 1500 1040
23
24
25 110 120 120 Y 0 1500 1040
26 110 120
You will notice that the graphic plot now looks a little odd. The reason for this is, that by default,
CAESAR II displays the system with Nodes and CNodes at the same point in space. This is fine for
connecting pipe nodes to structure CNodes (like in Tutor) or nozzle nodes to vessel/pump CNodes
(like in Turbo). But in this model, where several restraints reference the same CNode, the display
will still attempt to join all these Nodes and CNodes together, resulting in a 'nonsense' plot. To clean
up the plot and avoid the associated coordinate mismatch error during Error Check, change the
Configuration/Setup parameter Connect Geometry through CNODEs to False .
JrajjgiMjgj
.S x
I :HP Reset All Data Directory : O:\TR
TRAINING
7 \CAESARII\ -
iCategones El Bends
Bend Length Attachment Percent 1.000
0 Configuration Maximum Allowable Bend Angle 95.000
Computational Control 5,000
Minimum Allowable Bend Angle
Database Definitions 5.000
Minimum Angle to Adjacent Bend Point
FRP Properties El Input Items
Geometry Directives
AutuHudtfliluiilLlUl InuuilWlll
Graphics Settings
Miscellaneous Options
IfoTTTiTrzifernTTT;i'/ffirrairriiffTCWEEL |False E
I larmntot Thermal Dewing Tolernnaa O.flO&l
SIFs and Stresses 25 4000 mm.
Loop Closure Tolerance
Z-Axis Vertical False
Connect Geometry Through CNodes

Effects visible After Error Checked Immediately
The plot will not update automatically, so must be done manually. Click the Reset plot button to
refresh the graphics.
Restraints
*
Reset Plot
Restore to original size

S

INTERGRAPH0
The plot will once again look correct.
is
c
* *
Re -run the eror check - there should be no errors and no new warnings or messages.
I@ Br jt & ft. < >

~ *
i
Start Run
& 2
nings: 0
Load Case S tup

Access the Load Case editor - you will receive a message stating that the individual loads for the job
have changed. This message is due to the fact we now have displacement loads in the model D1and
.
D3 and the uniform loads Ul, U2 and U 3. These must be incorporated into our load cases Section
1621.1.4 discusses the combination method for the various loading directions. It states that the load
along each horizontal axis shall be applied independently, but in conjunction with the vertical load.
Since ISO 14692 only looks at a single stress type ( OPE), this leads to the following seismic load cases
(since boundary conditions are non-linear):
Note the +/- signs in the various cases

INTERGRAPH
"
Cool H20 - FRP Piping E 48
10
:Q 3 (Hi &
[
Load Case Editor Load Case Options Wind Loads ] Wave Loads

W - Weight L1 W+T1+P1 OPE
D1 - Displcmnt Case #1 L2 W+D1+T1+P1+U1+U2 OCC
D3 - Displcmnt Case #3 L3 W+D1+T1+P1+U1-U2 OCC
T1 - Thermal Case #1 L4 -
W-D1+T1+P1 U1+U2 OCC
PI - Pressure Case #1
L5 -
W-D1+T1+P1 U1-U2 OCC
L6 W+D3+T1+P1+U2+U3 OCC
U1 - Unif Load Cese #l
L7 W+D3+T1+P1-U2+U3 OCC
U2 - Unif Load Case # 2
L8 W-D3+T1+P1+U2-U3 OCC
U3 - Unif Load Case #3
L9 -
W-D3+T1+P1 U2-U3 OCC
WW - Water Filled Weight
L10 . . .
L1 L2 L3 L4 LS L6 L7 L8 L9 OCC
L11 . . . . . . . .
L1 L2 L3 L4 L5 L6 L7 L8 L9 OCC
Note that even though results only need be retained from two load cases ( the last two), we are
electing to keep results from all load cases in order to help us debug in the event of an overstress.
Load Cases L10 and Lll are not combined algebraically, rather they are included to compare the
displacements, forces and stresses. Hence why they arenot added or subtracted, just listed. We
wish to find the worst case load case, so we can get CAESAR II to compare the resluts from each load
case and report the maximum and minimum values.
Select the Load Case Options tab and select SignMin and SignMax for the Combination method for
L10 and Lll.
Load Case Editor Load Case Options wind Loads Wave Loads
Output Output Comb

Load Case Name Status Type Method
L1 OPERATING CASE CONDfTlON 1 Keep Disp/Force /Stress

L2 W +D1+T1+PI +U 1 +U2(0CC) Keep Disp/Force /Stress
L3 WTD1TT 1+P 1+U 1 -U2(OCC) Keep Disp/Force /Stress
L4 W-D1+T 1+P1-U1+U2(OCC) Keep Disp/Force/Stress
L5 W.D 1+T1+P 1-U 1-U2(OCC) Keep Disp/Force/Stress
L6 W+D 3 +T1+P 1 +U2 +U 3(OCC) Keep Disp/Force/Stress
L7 W+D3+ T 1+P1-U2+U3(OCC) Keep Disp/Force /Stress
L8 W -D3 +T 1+P 1+U2 -U3( OCC) Keep Disp/Force /Stress
L9 W -D3 + T1+P 1-U2 -U 3(OCC) Keep Disp/Force /Stress
L10 SUSTAINED CASE CONDITION 1 Keep Disp/Force/Stress SignMin
L11 EXPANSION CASE CONDITION 1 Keep Disp/Force/ Stress SignMax
SignMax compares the displacements, forces and stresses and uses the maximum force and
maximum stress value of the cases (i.e. sign is considered in the comparison). Displacements are the
maximum Signed valued of all displacements from each case included in the combination. Similarly

INTERGRAPH 0
CoolH 20 - FRP Piping IE49
for forces and stresses, these are the maximum Signed forces/stresses from each case included in
the combination.
SignMin is the opposite of this - the minimum signed values of the stresses/forces/displacements
are included.
Using SignMin and SignMax we can get the enveope of restraint loads for all cases.
Also for the static seismic cases, enter in the Occasional Load factor of 1.33.
Elbow Elbow Flange

Stiffening Friction Occ Load
Load Case Name Stiffening Analysis
Elastic Multiplier Factor
Pressure emperature
Modulus
L1 OPERATING CASE CONDITION 1 PMax EC 1 oooo 1 2390 lone
L2 VV+DI+TltPI+UI +U2(OCC) PM ax EC 1 0000 1 3300 lone
L3 W +DHT 1+P 1+U 1 -U2{OCC) PMax EC 1 0000 1 3300 lone
L4 VVD 1+T|+P 1 UI 4U2(0CC) PMax EC 1 0000 1 3300 lone
L5 W -D 1+T 1+P 1 -U 1 -U2(OCC) PMax EC 1 0000 1 3300 lone
L6 V\ND3 +T 1+P 1 +U2+U3(OCC) PMax EC 1 0000 1 3300 lone
L7 VV+ D3+THP 1-U2+U3(0CC) PMax EC 1 0000 1 3300 lone
L8 VVD3+TI 4PI+U2 U3(0CC) PMax EC 1 0000 1 3300 lone
L9 VV D3 rTHP 1-U2-U3(OCC) PMax EC 1 0000 1 3300 lone
L10 SUSTAINED CASE COIIDmON 1 1 3300 lone
L11 EXPANSION CASE CONDITION 1 1 3300 lone
L
Analyse the model.
Review Results
It can be seen straight away that there is an issue with Cases 4 and 5.
N Static Output Processor - [D:\TRAINING\C

File View Filters Reports Options PlotOptions Plot \
j & B Enaag) a = a EH*, jna
L* . ci + -
Load Cases Analyzed
1(OPE) W+T1+P1
2 (OCC) W+D1+T1+P1+U1+U2
3 (OCC) W+D1+T1+P1+U1-U2
4 (OCC) W -Dl -rTUPl-UUU2
5 (OCC) W- DUTUP1-U1-U2
6 (OCC) W+D3+T1+P1+U2 +U3
7 (OCC) W+D3 +T1+P1-U2 +U3
8 (OCC) W-D3 +T1+P1+U2-U3
9 (OCC) W- D3 +T1+P1-U2-U3
10 (OCC) 110 =11,12,13,14,15X6X7,18,19
11 (OCC) L11= L1,L2,L3,L4,L5,L6X7X 8 X9

INTERGRAPH
*
250
Notes:
You may get a failure in load case 10 rather than 11, depending on which load case you have
set to SignMin/SignMax
Ifyou get no failures in any cases, check the results, if you see a message NO CODE STRESS
CHECK PROCESSED in the stress report, the most likely reason for this is that the occasional
load factor is set to zero.
If you get additional load cases failing, check that you have a) entered in the displacement
-
CNode numbers for all restraints and b) entered the +/ operators correctly in the load case
setup - setting these wrong can result in having the earthquake force going in one direction
whilst the displacement goes in the opposite ( the displacement is caused by the earthquake
remember, so these should always be in the same direction
Finally, check that you have the Z restraint at node number 110
Reviewing the Load Case 11 confirms that the maximum stress fails the code stress check, and is at
103.8% of the code allowable at node 180.
In order to solve this, it is necessary to know which of the seismic combination cases caused the
failure. We can see straight away that it is either case 4 or 5. Reviewing the code compliance report
for all cases 2 to 9 shows that cases 4 and 5 are very similar alhough case 5 is fractionally higher.
Code Compliance
CAESAR II 2011 SP1 Ver.5.30.01, (Build 110228) Date: JUL 29, 2011 Time: 13:57
Job: D:\TRAINING\CAESAR II\COOLH20
CODE COMPLIANCE REPORT: Code Stresses on Elements
Various Load Cases
From Code Stress

Allowable _
TO
. Code Stress
Allowable
Stress Piping Code
joad case Node N./sq.mm.
Stress Node N /sq iran.
N./sq.mm. > >
N./sq.mm.
2(OCC) 180 17.32 21.30 428 10.14 21.30 ISO 14692

3(OCC) 16.98 21.27 10.21 21.27 ISO 14692
4(OCC) 22.35 22.05 10.63 22.05 ISO 14692 *
5(OCC) 22.69 22.02 10.42 22.02 ISO 14692 *
6(OCC) 15.06 21.03 8.06 21.83 ISO 14692
7(OCC) 15.14 21.80 7.95 21.80 ISO 14692
8(OCC) 15.85 21.59 7.48 21.59 ISO 14692
9(OCC) 15.98 21.57 7.40 21.57 ISO 14692
Cases 4 and 5 represent the-X,+Y and -X,-Y seismic loadings. Now we need to find out which
component of the seismic loadings caused the failure - the interial or the displacement. Stress due
to force-based load is a primary load, stress due to strain is a secondary load. Once we find out the
cause we can take the appropriate action to resolve the overstress situation.
An easy way to determine which is the worst cause is to run the components of the load case
individually to see wihich gives the greatest stress.
Return to the load case editor.
Load cases 4 and 5 both consist of W, Dl, Tl, PI, U1and U2.
I
(
INTERGRAPH
IL4 1 W-D1+T1+P1-U1+U2
| L5 J W-D1+T1+P1-U1-U2
.
We know that W+D1+T1+P1is not the cause as the OPE case is perfectly fine So the culprit must be
one of eiether Dl, Ul or U 2. Therefore, create three new load cases and assign D1,U1and U2
respectively to each load case .
L10 D1 OPE
L11 U1 OPE
L12 U2 OPE
After re-running the analysis review the code compliance report for the three new cases.
Code Compliance
CAESAR II 2011 SP1 Ver.5.30.01, (Build 110228) Date: JUL 29, 2011 Time: 14:16
*x
Job: D:\7RAINING\CAESAR II\COOLH20
CODE COMPLIANCE REPORT: Code Stresses on Elements
Various Load Cases
Allowable Allowable
From Code Stress Stress .. . Code stress Stress Piping Code
Load Case Node N./sq.mm. To Node N./sq.mm.
N./sq.rrm. N./sq.mm.
10(OPE) 180 12.35 19.64 428 6.13 19.64 ISO 14692

11(OPE) 0.23 19.29 0.16 19.29 ISO 14692
12(OPE) 1 2.16 19.31 2.35 19.31 ISO 14692
This shows that clearly the Dl components is the largest contributer to the overstress, by a long way.
This is a secondary loading, so the solution is to add more flexibility. In this case the fix is actually
very simple and involves simply removing the guide just before node 180 located at node 170.
The system will now pass the stress check.

INTERGRAPH
0
(13)Stresses
1
'
CAESAR I 2Oil sPI Ver.5.30.01, (Build 110228) Date: JUL 29, 2011 Time: 14:26
Job: D:\TRAINING\CAESAR II\COOLH20
STRESSES REPORT: Stresses on Elements
CASE 13 (OCC) L13=L1,L2,L3,L4,L5,L6 , L7, L8 , L9

Stress Stress
SIF In SIF Out Code Stress Stress Ratio Piping Code
NODE
N./sq.mm. Plane Plane N./sq.mm. N./sq.mm. %
N./sq.mm
Piping Code: ISO 14692 = ISO 14692 (2005)
CODE STRESS CHECK PASSED LOADCASE 13 (OCC) L13=L1,L2,L3 L4,L5,L6,L7,L8,L9

/
Highest Stresses: (N./sq.mm )

codestress Ratio (%): 63.5 @Node 180
Axial Stress: 2.1 @Node 140
Bending Stress: 11.2 @Node 180
Torsion Stress: 7.0 @Node 429
Hoop Stress: 10.1 @Node 240
3D Max Intensity: 13.5 @Node 180
(
INTERGRAPH
*
Gas Transmission Pipeline - Buried Pipe
& w
* !
\
<:
GASTRANS
W
N os
v. . R.
A
-,/Pf
? 5 5
.
* /
5
0
( g)
StS
tv & :S ! S S
-
A.
420 430 S 650 U
A i
.
See Sht 1 for continuation
( 2
Z53?V
A
VALVF /FLANFiF WFtGHTS

570-520 500 N
AJ 540-550 265 N
5 See Sht. 1 for continuation
-
590 600 480 N
(
INTERGRAPH
0
254
This model of a gas transmission pipeline will introduce the buried pipe modeller, and also introduce
fatigue analysis. We will also explore the requirements of the B31.8 Design Code.
This job consists of a 36 header, an 8 branch, and a 2 bypass, in the vicinity of a natural gas
compressor station. The lines immediately go underground, from where they continue indefinitely
for a very long distance.
B 31.8 Design Code

Gas transmission pipelines are covered by the B31.8 Code - Gas Transmission and Distribution Piping
Systems. The philosophy of this code is to use high strength steel and custom, optimized wall
thicknesses wherever possible, in order to minimize the amount of steel used in the long cross
country pipelines. Stress analysis-wise, the code seeks to prevent yielding under any set of load
.
cases This prevents catastrophic failure under primary loads, and prevents plastic deformation
under secondary loads. There are no requirements for reducing allowables for cyclic reduction
.
factors (i.e , fatigue requirements).
B31.8 is one of the few codes in which the OPErating case is a Code case and the EXPansion case is
not
Requirements of the different design codes are listed here in the table:-
B31.1 B31.3 B 31.4 B31.8 B31.4 CH IX B31.8 CH VIII

OPE NO NO YES YES YES YES
SUS YES YES YES YES YES YES
EXP YES YES YES NO NO NO
Modelling the system

.
Model the system as shown in the isometric sketches The following issues are of specific interest
during the modelling phase.
Element 10-20 originates at (and is anchored at) the compressor connection, with a flange ( 250 mm
long, 5780 N weight). The pipeline is 36 diameter, with a non-standard 18 mm wall thickness.
Enter two temperatures to model the extremes of the operating range, which represents the
expectations due to winter lows and summer solar gain:
Ambient = 21 C (set in Config)
T1 = 50 C, T2 = -5 C above ground ON THE FIRST ELEMENT
T1 = 30 C, T2 = 10 C underground (we will use these temperatures later)
The material is API -5L X65 (material no 306), high strength steel. Its parameters can be found in the
CAESAR II material database.
The applicable code is B31.8
For natural gas, fluid density may be neglected.
The branch connection at node 30 (as well as all other branches) is a Weldolet (SIF type 5).

INTERGRAPH
The restraint at node 40 (as well as those at nodes 80, 110, 320, 360, 420, and 450) is a +Y (weight
only) restraint. Specify a coefficient of friction of 0.3 for steel-on-steel contact.
The bends at nodes 60 and 70 are 3-diameter bends (radius = 1370 mm).
.
Element 60-70 goes underground 685 mm below node 60 Therefore we will need a node to indicate
.
where the above ground/underground transition takes place The entire element 60-70 can be
entered first, and then the Break command can be used to insert a node 65 one-third of the way
along the element length.
Edit Deltas
Length
DX .fililiHiIOWi'iil j Length: 5405.833 mm
DV: -2055 000 mm
Direction Cosines
DZ: Cos
* [-0.925
Offsets CosY |-0.380
CosZ [ o.ooo
The element can be determined to be 5405 mm long (by clicking the local cosine button) so one-
third of that length is 1802.
@ Insert Single Node

New Node Number 65
Distance
ln (mm )
from Node 60 1802 000 mm
from Node 70
The temperatures on 65-70 should be changed to T1= 30 C, T2 = 10 C.
The valve at element 90 - 100 (as well as that at element 430-440) is supported within an accessible
valve pit (covered, but not buried). Node 75 (as well as nodes 115, 405, and 445) represents the
buried/non-buried transition, and will be used later .
.
Element 115-120 extends indefinitely, in a straight run, underground Obviously, we need not model
it forever - at some point, the cumulative restraining effect of the soil acts as an anchor. We will
determine the required modelling length later; for now we can put in a dummy length of 10,000
mm.
The model of the main pipe will look like the one shown below:

INTERGRAPH

Now move on to the branch, starting with element 30-310. This is an 8 standard schedule pipe. The
temperatures on this element should be restored to T1= 50 C, T 2 = -5 C. The bends on this line are
standard Long Radius. This pipe is now A53 Gr B low carbon steel.
Element 30-310, modelled as is, is deceptively flexible, with a modelled length of 2440 mm, and an
actual length of 1980 mm (since the element really originates at the surface of the 36 header, not
at the centreline ). So in reality, its flexibility should only be (1980/ 2440)3, or roughly 50%, of that
calculated. We could correct this by modelling a weightless rigid from the centreline of the header to
surface of the header (i.e., element 30-305), and then begin modelling the 8 line from that point
(i.e., element 305-310).
This approach has the following problems:
1. Placing the weldolet at node 30, causes no stress intensification on the 8 line (since there is
no stress calculated on the rigid, and no weldolet at node 305).
2. Alternatively placing the weldolet at node 305 intensifies the stress on the 8 line, but
doesn't intensify the stress on the 36 line. Furthermore, the SIF would be both
miscalculated (since CAESAR II would think the header size would be that of the rigid
element) and misapplied (CAESAR II would not be able to determine in-plane from out-plane
since the SIF would be at applied to two co-linear elements ).
One solution to this modelling dilemma is to use an OFFSET, in this case modelling a From Offset of
.
457 mm in the Z-direction This internally models element 30-310 as a 457 mm long rigid element
connected to a 1980 mm pipe, and transfers all stress calculations out to the true start of the 2440
mm pipe. (Note Offsets may not be entered on bend elements, so in this case, it is first necessary to
break element 30-310 into two elements. Be careful that no elements, after applying Offsets, are
reduced to zero-length. So in this case, enter two elements, 30- 305 (DZ = 1000 mm, From Offset Z =
457 mm) and 305-310 (DZ = 1440 mm, long radius bend).

(V
INTERGRAPH
*
>>
From 30
To 305|
Offset From

DX X
DY
Y:
DZ 1000.000 mm
Z: 457.000 mm
3 Offsets

From 305 J Bend
Nome Rigid
To 310
Expansion Joint

ox Restraints
DY Hangers
[ Nozzle Flex
DZ: 1440.000 mm
Forces/ Moments
Offsets
Uniform Loads
Element 370-380 goes underground 685 mm below node 370, so we need a node to indicate where
the above ground/underground transition takes place. The entire element 370-380 can be entered
first, and then the Break command can be used to insert a node 375, 685 mm along the element
length. The temperatures at node 375 should be changed to T1= 30C, T2 = 10C.
The valve at element 430-440 is supported within a valve pit. Nodes 405 and 445 represent the
buried/non-buried transition.
Element 445-450 (like element 115-120) extends indefinitely, in a straight run, underground. We will
determine the required modelling length later; and use a dummy length of 10,000 mm for now.
The completed model will look like the one shown below:
c
1
1
v
rs: r
f
K
INTERGRAPH
*
258
Next model the bypass. Create this model in a new file before combining the two files.
Combine the models and run the error check.
Two errors will appear. Both errors relate to the temperature for case 2, at elements 10- 20 and 30-
BOS. The temperature for case 2 at these locations is -5C. The error message is showing that there
is no material data available for either of the two materials we have selected for a temperature this
low, in the B31.8 code.
Errors and Warnings

IErrors: 2 Warnings: 0 Notes: 0
Message Element/
Number Node Number
1 ERROR 60E -
10 20 On element 10 to 20 the TEMPERATURE for case
is OUTSIDE the allowed range for this material .
2
2 ERROR 60E -
30 305 On element 30 to 305 the TEMPERATURE for case
is OUTSIDE the allowed range for this material .
2
We cannot analyse until this has been corrected. To correct, we can edit the material database to
include properties for the material down to the correct temperature.
(
INTERGRAPH
*
Material Database
Close the piping input to return to the main window. Access the material database form the Tools
menu.
Ii D O 0 ra ( Configure/Setup
Make Units files
Convert Input to New Units
S3 Material Data Base .
Accountina
Choose to edit a material
|! & & ss,

File
* 1
Edit Material View

13
| Edit a material
Search for material 102 (A53 B) (you can search on either term). Notice that there are a number of
entries for A53 B for the various different codes, including for B31.8 Select the B31.8 entry .
iflEicaiBiiiaataanait
Type the name or number of a material

102 Search
Double Click on the material name (or selection.
Material Nome Number Piping Code

A53 B 102 All Codes
A53 B 102 B31.1
A53 B 102 B31.3
A53 B 102 B31.4
AF1R m? R }1 5
| Is 102 B31.8
D
SA-53 B 102 ASME NC
-
RA 53 R m? ASMF NH
The lowest temperature for which an expansion coefficient is entered is 0 C The next row down is - .
73.3C, which has no expansion coefficient. As our temperature in the model is -5, we can see
where we have incomplete data. We could enter in the data here for the missing expansion
coefficient.
Temperature Exp. Coeff. Allowable Stress Elastic Modulus Yield Stress Ult Tensile Strenqth
1 -73 33778 2.082169 e+008 241 311 413 676
2 0 001420975 10 85313 2.047696 e+008 241 311 413 676
3 15 55822 11 2491 2.033907e+008 241 311 413 676
4 21 11422 112491 2.033907e +008 241 311 413 676
5 37 78222 11 2491 2.020118 e+008 241 311 413 676
Alternatively, using engineering judgement, we can take the material properties for A 53 B from
another code where the data is filled in sufficiently and use this in B 31.8 code.
V.
(
INTERGRAPH
*
260
Search again for the material A 53 B. This time, select the All Codes data. This information is more
complete than the B31.8 specific data for A53 B.
If we are confident that this data will be suitable for B31.8 then we can use this data in place of the
default B31.8 data.
Temperature Exp. Coeff . Allowable Stress Elastic Modulus Yield Stress Ul

1 -198 3478 8 99928 2164904e + 008 241 311
2 -128 8978 9 62923 2123537e+008 241 311
3 -73 33778 9 899208 2 082169e+008 241 311
4 45 55778 10 43917 2 061485 e+008 241 311
5 21 11422 10 92513 2 033907e+008 241 311
6 37 78222 11 03312 2 027012e+ 008 241 311
7 93 34222 11 48308 1 985645 e+ 008 221 3167
The material database is stored in two files. One file is CMAT.bin. This stores all the default data
.
and is read only Any changes to the material are stored in a separate file called UMAT.UMD. This
.
file stores any material information which is different to that in CMAT.bin CAESAR II then uses the
UMAT.UMD file first, and reads any further data from CMAT.bin.
Materials from CMAT.bin cannot be deleted, only those from UMAT.UMD.
If we save the A 53 B B31.3 material data for use with B31.8, this will be written to the UMAT
database. The CMAT database will be still the same as it currently is, however the UMAT will be
read in preference to this, and it will act as though the data has been overwritten .
To make this change, simply select the Applicable piping code drop down, and change from B31.3 to
B 31.8 and save the material.
Applicable Piping Code: B31.3

'
I B3 1 . 1
ve (A-D): B31.3
Temperature Curve
B31.4
ms Ratio: [B31.5
Poissons
~
|=ETOir N 1
IB31.9 H
B31.ll
Fh /Fa UeucMr
(
.
Return to the input You should see a warning stating that the properties for the material A53 B,
code B31.8 have changed in the material database, and given the option to use these new properties
or keep the existing. Select to update the material properties via the No - Update button.
Material Warning 3
Properties for material

# 102. A53 B. code B31 8
have changed in the material database

Do you want to keep the existing material properties?
Yes - Keep No - Update Details

INTERGRAPH
*
261
Select part of the bypass (or any part that is material A53 B that we have just changed) and double
.
click on the chevron in the temperature/pressure area Notice that the expansion coefficient is now
filled in for both temperatures (whereas it was 0.000 for T2 previously).
Re-running the error check will show that the error is no longer present, for material A 53 B but still
present for API-5L X65. We now need to update the material database for this material.
Repeat the exercise from before and update the material properties for API-5L X65.
Properties for material

. .
# 306 API-5LX65 code: B 31.8
have changed in the material database.

( Do you want to keep the existing material properties?
Yes - Keep No - Update Details
Run the error check again - the material errors will no longer appear. The error checler should show
only the Centre of Gravity report.
1Errors; 0 Warnings: 0 Notes: l
Message Element/
Message Type Number Node Humber Message Text
1 MOTE
N. mm. mm , mm .
Pipe
Insulation
297911.8
0.0
-19525.3
0.0
-1714.0
0.0
730.9
0.0
Refractory 0.0 0.0 0.0 0.0
Fluid 0.0 0.0 0.0 0.0
Pipe+Ins+Rfrty 297911.8 -- 19525.3-1714.0 730.9
19525.3 -1714.0
Pipe+Fluid 297911.B 19525.3 1714.0 730.9
Pipe+Ins+P.frty+Fld 297911.B - - 730.9

INTERGRAPH
*
262
Buried Pipe Modeller

.
The piping system beyond nodes 65 and 375 is mostly buried The effect of this is
(1) It will be continually supported, causing the weight stresses to be negligible,
(2 ) It will be continually restrained against axial growth and bending by the adjacent soil.
The former effect can be best modelled by zeroing the density of any pipe, fluid, and insulation; the
latter can best be modelled by meshing the pipe and adding restraints, with mesh spacing, restraint
stiffness, etc. based upon the soil properties. CAESAR II provides an underground pipe modeller
which simplifies this process, performing the following functions:
Allows for the direct input of soil properties. These properties are used to generate first the
stiffnesses on a per length of pipe basis, and then the restraints that simulate the discrete
buried pipe restraint. (Note that any existing restraints in the underground area are deleted
during this process.) CAESAR II supports three different soil modellers - one based upon the
published work of Mr. L. C. Peng, plus two others (for clay and granular soils ) from the
American Lifelines Alliance.
Automatically breaks down straight and curved lengths of pipe. CAESAR II uses a three Zone
concept to break down straight and curved sections. Those ends of pipe identified as
transverse bearing lengths are broken down into Zone 1 lengths (the smallest element
lengths selected to properly distribute the lateral forces to the soil). At distances far away
from Zone 1are Zone 3 lengths (long lengths of pipe selected to transmit axial loads).
Between Zone 1and Zone 3 is Zone 2 (transition lengths which vary linearly from the Zone 1
end to the Zone 3 end).
Allows for the direct input of user' s soil stiffnesses on a per-length of pipe basis. Input
parameters include axial, transverse, upward, and downward stiffnesses, as well as ultimate
loads. The user can specify user-defined stiffnesses separately, or in conjunction with
CAESAR ITs automatically generated soil stiffnesses.
Restraint Parameters
The Underground Pipe Modeller allows the use of any of three different soil modelling algorithms
The first two are based upon the work of the American Lifelines Alliance, as published in their
document Guidelines for the Design of Buried Steel Pipe , dated July, 2001 (with addenda through
February 2005); this document offers different models for clay soils and granular (sand/gravel). The (
third model is based on the soil restraint modelling algorithm presented by L.C. Peng in his two-part
paper entitled "Stress Analysis Methods for Underground Pipelines," published in 1978 in Pipeline
Industry. Soil supports are modelled as bilinear restraints having an initial stiffness, an ultimate load,
. ..
and a yield stiffness The yield stiffness is typically set close to zero, i e once the ultimate load on the
soil is reached there is no further increase in load even though the displacement may continue. The
basic ultimate loads that must be calculated to analyse buried pipe are the axial and three bearing
(transverse, upward, and downward) ultimate loads. ( Note that for the Peng model, all three bearing
ultimate loads are considered to be identical.) Once the axial and bearing ultimate loads are known,
the stiffness in these directions can be determined by dividing the ultimate load by the yield
displacement. (Researchers have found that the yield displacement is typically related to the buried
depth, the pipe diameter, the soil type, and the load type.) The ultimate loads and stiffnesses
(
INTERGRAPH
263
computed are on a force per unit length of pipe basis; the restraint ultimate loads and stiffnesses are
then based upon tributary lengths of the adjacent piping elements.
Idealized N
Actual
45 /2
* Displacement
Upward .
b Downward .
c Sideward .
d Force displacement
The restraint equations use these soil properties to generate ultimate loads and stiffnesses using the
following equations.
Initial restraint stiffness is estimated by assuming that the Ultimate Load is developed over a Yield
Displacement (YD). Axial Stiffness (KAX) on a per-length of pipe basis:
FAX
KAX
YDAX
Transverse stiffness ( KTR) on a per-length of pipe basis:
FTR
KTR YDTR
American Lifelines Alliance Clay Model

Lateral Ultimate Load ( FAX) per unit length
FAX = nDac
YDAX = 0.3 inches (stiff clay) or 0.4 inches (soft clay)

Where:
D Pipe diameter
a = soil adhesion factor (dimensionless )
= 0.608 - 0.123 c - c 2 1 c3 l
+ +
c : soil cohesion representative of soil backfill

INTERGRAPH
*
Transverse Ultimate Load ( FTR) per unit length
FTR NCHCD
( |) < 0.1Dto 0.15D

YDTR = 0.041 tfW +
Where:
D
A = 6.752
B = 0.065
C = -11.063
D = 7.119
H = height of soil cover (measured to centre of pipe, note CAESAR II requests distance
to top of pipe )
Downward Ultimate Load (F0), per unit length
FD = NccD + NQ y' HD
YD0 = 0.2 D
Where:
Nc = 5.14
NQ = 1.0 (for clay)
y' = defective density of soil (taking buoyancy into account )
Upward Ultimate Load (Fu), per unit length
Fu = NcvcD
YDU = 0.1W ( stiff clay ) to 0.2H ( soft clay ) < 0.2 D
Where:
Ncv = 2 < 10

INTERGRAPH
0
American Lifelines Alliance sand model:

Axial Ultimate Load ( FAX), per unit length
y'(1 + K0 )
FAX = n DH - - tan 6
YDAX = 0.1 inches ( dense sand)or 0.2 inches (loose sand )
Where:
K0 = coefficient of pressure at rest (dimensionless ) = 1 sin
S = interface angle of friction for pipe and soil = f 4>
<t> = soil angle of internal friction, typical values are:
27 - 45 for sand
26 - 35 for silt
coating dependant factor (dimensionless ), typical values are:
Pipe Coating f
Concrete 1.0
Coal Tar 0.9
Rough Steel 0.8
Smooth Steel 0.7
Fusion Bonded Epoxy 0.6
Polyethylene 0.5
Transverse Ultimate Load (F ), per unit length
FTR = NQHy' HD
YDTR = 0.04 tf + ( Y) < 0.1 D to 0.15D

Where:
NQH = A + BX + CX 2 + DX 3 + EX 4
A, B, C, D, E based on <(>, according to the following table:
$ A B C D E
20 2.399 0.439 -0.30 1.059E -3 -1.754E-5
25 3.332 0.839 -0.090 5.606E -3 -1.319E-4

INTERGRAPH

266
30 4.565 1.234 -0.089 4.275 E-3 -9.159 E-5

35 6.816 2.019 -0.146 7.651E-3 -1.683 E -4
40 10.959 1.783 -0.045 5.425 E-3 -1.153 E-4
45 17.658 3.309 -0.048 6.44E -3 -1.299 E-4
Downward Ultimate Load (FD), per unit length
, NyyD2
FD = NQy' HD +
YDD = 0.1D
Where:
p
= e(re tan < ) tan2 (45 +
NQ
_ e( .
0.18< > 2 S)
Ny
*
y = density of dry soil
Upward Ultimate Load (Fu), per unit length
Fu = NQVy' HD
YDa = 0.01W (dense sand) to 0.02 H (loose sand) < 0.1D
Where:
NQV nQ
Meshing Parameters
Typical buried pipe displacements are considerably different than similar above ground
displacements. Buried pipe deforms laterally in areas immediately adjacent to changes in directions
(i.e. bends and tees); in areas far removed from bends and tees the deformation is primarily axial.
The optimal size of an element (i.e., the distance between a single FROM and a TO node) is very
dependent on which of these deformation patterns is to be modelled. Where the deformation is
lateral smaller elements are needed to properly distribute the forces from the pipe to the soil. The
length over which the pipe deflects laterally is termed the lateral bearing length (Lb) and can be
calculated by the equation:
El 1/ 4
4-A
(
4 = .75
*( )
Where:
E = Pipe modulus of elasticity

/ = Pipe moment of inertia

INTERGRAPH
*
267
CAESAR II places three elements in the vicinity of a bearing span to properly model this load
distribution. The bearing span lengths in a piping system are called the Zone 1lengths. The axial
displacement lengths in a piping system are called the Zone 3 lengths, and the intermediate lengths
in a piping system are called the Zone 2 lengths. Zone 3 element lengths (to properly transmit axial
loads ) are computed by 100 * D, where D0 is the outside diameter of the piping. The Zone 2 mesh is
comprised of elements that are 1.5 times the length of a Zone 1element at its Zone 1end, and that
are 50 * Do long at the Zone 3 end. A typical piping system and how CAESAR II views this zone mesh
distribution is illustrated below :
#3
#1
#2
( #2
#1
nr
#1
#2
#1 #2 #3
#1
#3
#2
(Buried)
#1 Enter Soil
+
(Unburied)
Schematic of the 3 Buried Zones

used in CAESAR II:
Zone 1 (#1) bearing

( Zone 2 (# 2) transition from #1 to #3
Zone 3 (# 3) axial friction

INTERGRAPH
268
Virtual Anchor Length ( VAL ):

Since soil restraint capacity is a function of piping length, after a certain length, the soil restraints will
fully counteract the piping loads, acting as a virtual anchor . The piping need not be modelled
beyond this length. This length can be calculated as that length where the axial pipe force equals the
ultimate axial restraint load.
Axial pipe force consists of three types:
1. Thermal Load = EaAtemp D nt

2. Poisson effect (longitudinal shrinkage due to hoop strain) = v PD 2 n / 2
3. Longitudinal pressure load = PD 2 n / A
Using the ( ALA Sand Model), the Axial Ultimate Load ( FAX) per unit length is:
FAX = n D H t a nS
The ultimate restraint load therefore is the VAL * Fax ,or:
Ultimate restraint load = V A L x [ 71 D H

y K
tan
PD 2 n PD 2 n y ' (i + K0 ) . ,
EaAtemp Dnt -v -2 H 4 = VAL x n DH tan 6
Simplifying this gives :
( ) (0.5 - v)] / \Hy' 12+ K

( 0)
[
VAL = EaAcemp t + tan <p
This value can be used to determine how long we must model elements 130-140 and 460-470 of the
GASTRANS model. This pipeline is in sandy soil - the soil parameters are as follows.
(
Soil Parameters
Soil Type Dense Sand

Coating Factor (rough steel) 0.8
3
Dry soil density, y 1909 kg/cm
Effective Soil density, y' 1190 kg/cm3
Buried Depth, H 915mm (36 pipe)
610mm (8" pipe)
Angle of internal friction, 4> 35
Coefficient of Pressure at rest, Ko 0.426
Yield Displacement Factor, Axial dT 2.5mm
Yield Displacement Factor, Lat, cf/ fmult of D): 0.1
Yield Displacement Factor, Up, dQu of H): 0.01
Yield Displacement Factor, Up, dQu (max mult of D): 0.1
Yield Displacement Factor, Down, dQd ( mult of D): 0.1

INTERGRAPH
CADWorxe & Analysis Solutions
269
E = 2.034 5 N / mm2
a = 11.214 E 6 mm / mm / C
Atemp 12C (coldest temp underground is 10Cso delta from ambient of 21.11Cis about 12C)
t = 18mm (36" pipe) , 8.1788mm (8" pipe)
v = 0.292
P = 80 bar
D = 914.4mm (36 pipe) , 219.075mm (8" pipe)
Working this out give the following Virtual Anchor Lengths:
VAL36 = 206400mm
VALa = 127600mm
Unlike the perfectly rigid/perfectly plastic response due to friction alone, the CAESAR II soil modeller
inserts elastic/plastic springs to model some initial give in the soil. The program, therefore, may
require more pipe length to fully develop this virtual anchor along a straight run. Since an even
longer straight run is just as quick to enter and analyse, a more generous VAL length can always be
used in the model. For this example we will change the place -holder lengths originally entered for
elements 115-120 and 445- 450 to 300000mm and 200000mm, respectively.
>>
From 115 From: 445
Name (3 Name
To 120 To: 450

DX. 300000 000 mm DX -200000 000 mm
DY DY:
DZ DZ:
Offsets Offsets
Bury Pipe
We will now bury the pipe. Close the piping input and return to the main window. Access the
Buried pipe modeller
RiflteW SBlfciin
Piping 0
E3 Underground .
H Structural Steel
As soon as the buried pipe modeller is opened, the job file is saved as a copy with the same name
with suffix B
=" Buried Pipe Modeler - [D:\TRAINING\CAESAR II\GASTRANS COMPLETES]1

| File bciit View Buried Pipe

INTERGRAPH
*
In the underground modeller the soil underground conditions can be defined. This is done in two
parts:
1. Enter the soil model

2. Define where/how the system is buried
First let us define the soil model. We must define two soil models for our job - one for 915 mm
depth, one for 610mm depth.
Access the soil model entry dialog.
We will use the American Lifelines Alliance Sand method. Notice that this is soil model number 2.
Soil model number 1is reserved for a completely user defined stiffness which can be entered in the
main spread sheet.
Soil Model 1 Of 1 Add New Soil Model
Model Number 2 Delete This Soil Model

p-,
(Foil Model Type American Lifelines Alliance
Soil Classification Clay

Sand/Gravel
Enter the soil properties as detailed above.
F COATING FACTOR 08
GAMMA - DRY SOIL DENSITY ( kg /cu . m ) 1909
GAMMA PRIME - EFFECTIVE SOIL OENSITY (kg/cu m ) 1190
H - BURIED DEPTH TO TOP OF PIPE (mm ) 915
FRICT. ANGLE (Sand=27-45 . Silt =26-35 Clay=0)(deg) 35
KO - COEFFICIENT OF PRESSURE AT REST 0 426
dT - YIELD DISP FACTOR AXIAL (mm ) 25
dP YIELD DISP FACTOR LAT MAX MULTIPLE OF D 01
.
dQu - YIELD DISP FACTOR UPWARD , MULTIPLE OF H 0 01
.
dQu - YIELD DISP FACTOR . UP MAX MULTIPLE OF D 01
dQd - YIELD DISP FACTOR DOWN, MULTIPLE OF D 01
THERMAL EXPANSION COEFFICIENT xE- 6 (L/L/deg C ) 11 214
TEMPERATURE CHANGE Install -Operating ( deg C ) 12

(
INTERGRAPH
*
Add a second soil model, model no 3 and enter the properties for the second model Only the depth .
op of pipe (H) is different.
Soil Model 2 of 2 Add New Soil Model
Mode! Number 3 Delete This Soil Model

Soil Model Type American Lifelines Alliance w
Soil Classification Clay o Sand / Gravel
F COATING FACTOR 08
GAMMA - DRY SOIL DENSITY (kg/cu m ) 1909
GAMMA PRIME - EFFECTIVE SOIL DENSITY (kg/cu m ) 1190
H - BURIED DEPTH TO TOP OF PIPE (mm ) 610
FRICT ANGLE (Sand=2745,Silt=26 -35 . Clay=0)(deg) 35
K0 - COEFFICIENT OF PRESSURE AT REST 0426
dT - YIELD DISP FACTOR AXIAL (mm ) 2.5
.
dP - YIELD DISP FACTOR LAT, MAX MULTIPLE OF D 01
dQu - YIELD DISP FACTOR UPWARD. MULTIPLE OF H 0 01
.
dQu - YIELD DISP FACTOR UP MAX MULTIPLE OF D 01
dQd - YIELD DISP FACTOR DOWN. MULTIPLE OF D 01
THERMAL EXPANSION COEFFICIENT xE- 6 (UlVdeg C ) 11 214
TEMPERATURE CHANGE Install-Operating ( deg C ) 12
Now that the soil models have been created, we must specify where/how the system is buried. This
is done in the main Buried Element description Spread sheet .
SOIL FROM TO USER DEFINED ULTIMATE USER DEFINE

MODEL END END
.
FROM TO IIO. MESH MESH LATERAL K" LATERAL LOAD AXIAL STIF
MODE HOPE
115 120 2
14
15 30 305 - 0
0
0
0
16 305 310 0 0 0
17
1B
310
320
320
330
0
0
n
J
:L 0
0
0
0
19 330 340 o 0 0
20 0 350 0 0 0
21 350 360 0 0 0 0
22 360 370 0 0 0 0
23
24
370
375
375
380
0
3
a J 0
0
0
0
0
0
25 380 390 0
26 390 400 J 0 0 0
27 400 405 3 a 0 0
20
i 410 0 0 0
29 420 0 0 0
30 420 430 0 J 0 0
31 430 440 0 0 0
32 440 445 _ 0 0
33 445 450 0 0
r
Ready MUM
This spread sheet is used to indicate where the pipe is buried, under which soil type, which mesh
type should be used, as well as any user-defined stiffnesses. A critical part of the modelling of an
underground piping system is the proper definition of Zone 1(or lateral) bearing regions These .
regions primarily occur:
On either side of a change in direction

For all pipes framing into an intersection
At points where the pipe enters or leaves the soil

INTERGRAPH
6
CAESAR II automatically puts a Zone 1 mesh gradient at each side of the pipe framing into an elbow,
it is the user s responsibility to force it to do so in other areas. This is done using the FROM/TO end
mesh columns in the spread sheet. A tick in either of these columns places a zone 1 mesh at the
.
corresponding element end ( either From or To end) This should be done where the soil enters or
leaves the soil, in the vicinity of tees, or in problem areas .
The soil model number is used to specify whether the soil is buried
Complete the spread sheet using the following information .

The pipe enters the soil into soil model 2 at node 65, then leaves again at node 75. Enter soil model
2 on element 65-70. On the 'from end' of this element (i.e. node 65) place a Zone 1mesh by
checking the box - this is where the pipe enters the soil. The soil model will propagate through the
spread sheet, so enter 0 on element 75-80 (the pipe is now in the valve pit, out of the soil). On the
.
previous element, place a zone 1 mesh on the from end (i.e node 75) - where the pipe exits the soil.
SOIL FROM TO
MODEL END END
FROM TO
NO. MESH MESH
NODE NODE
6 60 65 0
7 65 70 2 0
8 70 75 2 0
9 75 80 0
Contir uing on, the pipe re-enters the sc il at node 115 through to the VAL at node 120.
SOIL FROM TO
MODEL END END
FROM TO
NO. MESH MESH
NODE NODE
13 110 115 0
14 115 120 2 0
15 30 305 0
Next moving on to the 8 pipe line, the pipe enters the soil at node 375, into soil model 3 and
remains in the soil until it exits at node 405 at the next valve pit. The one 1meshes at the bends will
be automatically added, we only need to define these at the entry and exit points.
SOIL FROM TO
MODEL END END
FROM TO
NO. MESH MESH
NODE NODE
23 370 375 0
24 375 380 3 0
25 380 390 3
26 390 400 3
27 400 405 3 0
28 405 410 0
The pipe re-enters the soil at node 445 through to the VAL at node 450. Nodes 50 through to the
end are the bypass, and so are above ground.
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INTERGRAPH
273
SOIL FROM TO
MODEL END END
FROM
NODE
TO
NODE .
NO MESH MESH
32 440 445 0
33 445 450 3 0
34 50 510 0
After completing the spread sheet, the model can be buried using the Convert Input function.
CM jt
i Buried
"y
; sea Convert Input
. Soil Models
I
You will receive a warning during the conversion stating that any user defined intermediate nodes n
bends will be deleted - CAESAR II will re-specify these as per the soil meshing algorithm during
conversion . Accept this message.
EARNING
User defined nodes on the bend curvature will

be deleted . CAESAR II spaces these nodes automatically .
The model will finish converting and will confirm that there were warnings - we only had the one
which is OK.
Clicking OK will close the buried pipe modeller. The currently selected c2 job file is now the buried
pipe model - GASTRANSB. This is identical to any other c2 job file, the only difference between this
model and the unburied'' model is the inclusion of a number of restraints with the correct stiffness
added as per the soil models input. Return to the piping input to view the updated buried model .
1
*
INTERGRAPH

Load Case Setup

In order to get the true Expansion Stress in a non-linear system, it is necessary to evaluate the
following load cases:
Extreme hot operating condition

Extreme cold operating condition
For this example, this can be implemented as:
W+P1+T1(OPE ) HOT
W+P1+T2 (OPE ) COLD
W+Pl (SUS)
LI - L2 ( EXP)
L3 + L4 (OPE )
CAESAR II recommends the following set of load cases to perform these analyses.
j . ..
:rjvTTnnrairrjiiir >Ku nT n
The following load cases are recommended to satisfy expansion and sustained code compliance requirements
Cas Load Cose Description

1 W+T1+P1(OPE) OPERATING CASE CONDITION 1
2 W*T2 *P1(OPE) OPERATING CASE CONDITION 2
3 W*P1(SUS) SUSTAINED CASE CONDITION 1
A L1-L3(EXP) EXPANSION CASE CONDITION 1
Use Recommended Cases ?

~
| Yes | | No _
This load case setup requires some minor modification. We need to add a third expansion check on
the stress range between operating case 1and 2, along with a baseline for these expansion cases, of
the weight no contents of the pipe, which will be used rather than the sustained case. Add the
following load cases:
L3 WNC
L7 LI - L2

(
INTERGRAPH
*

W - Weight L1 W+T1+P1 OPE
T1 - Thermal Cese #1 L2 W+T2+P1 OPE
T2 - Thermal Case #2 L3 WNC SUS
P1 - Pressure Case #1 L4 W+P1 SUS
WW - Water Riled Weight L5 L1-L 3 EXP
L6 L2-L3 EXP
L7 L1-L2 EXP
Also give the load cases meaningful names in the Load Case Options tab
Load Case Editor | Load Case Options | Wnd Loads l Wave Loads ]
Output Output
Load Case Name
Status Type
L1 Extreme Hot Keep Disp/Force/Stress

L2 Extreme Cold Keep Disp/Force/Stress
L3 Expansion Baseline Keep Disp/Force/Stress
L4 Sustained Stress Keep Disp/Force/Stress
L5 Shakedown Hot Keep Disp/Force/Stress
L6 Shakedown Cold Keep Disp/Force/Stress
L7 Shakedown Hot to Cold Keep Disp/Force/Stress
We can now run the analysis
Results Review
The results show that the system is acceptable. Now move on to the fatigue evaluation.

INTERGRAPH

Fatigue
Due to the danger of gas leaks, and the presence of cyclic loading (pressure fluctuations and solar
heat/cooling cycles) this system is being evaluated for fatigue failures. Since B31.8 does not offer any
specific guidance on fatigue analysis, our best course of action is to calculate the cyclic stresses
according to the Stress Intensity equation, and compare them to ASME Section VIII Division 2 fatigue
curves ( Figure 5.110.1), using an appropriate factor of safety.
This system should be evaluated for the following load cases:

Design life: 40 years
Temperature variations:
Ambient temperature: 21C
Summer maximum temperature, above ground: 50C (for 40 years) (Tl)
Summer maximum temperature, below ground: 30C ( for 40 years) (Tl)
Winter minimum temperature, above ground: -5C (for 40 years) (T2 )
Winter minimum temperature, below ground: 10C (for 40 years) (T2)
Daily temperature variation, above ground: 20Cfrom extreme (14,600 days) (T3=T1-A,
T4=T2+A )
Daily temperature variation, below ground: 10C from extreme (14,600 days ) (T3=T1-A,
T4=T2+A )
Pressure variations:
Maximum pressure: 80 bar (PI)
Annual shutdown: 0 bar ( 40 times )
Minimum operating pressure: 63 bar, varies between 63 and 80 (1,000 occurrences) ( P2 )
Daily fluctuation: 5 bar drop (14,600 days) (P3=P1-A )
.
Setting up the Fatigue I oad cases
Fatigue loads are incurred by transitioning between two or more different operating cases. It is
usually best to model the two extreme load cases, and set up all fatigue load cases to be a variation
from one of these. For example :
Operating Case A: Shutdown, winter minimum (extreme stress condition)

Operating Case B: Full pressure, summer maximum (extreme stress condition)
Operating Case C: Full pressure, winter minimum (enveloped in A-B cycle)
Operating Case D: Compressor operation, winter minimum
Operating Case E: Compressor operation, summer minimum fluctuation
Operating Case F: Pressure fluctuation, winter minimum
Operating Case G: Pressure fluctuation, summer minimum fluctuation
Operating Case H: Full pressure, winter maximum fluctuation
This translates into operating conditions of:
Tl = 50 AG, 30 BG (summer maximum)

T2 = -5 AG, 10 BG ( winter minimum)
T3 = 30 AG, 20 BG (summer minimum)
T4 = 15 AG, 20 BG (winter maximum)
(
(
INTERGRAPH
PI = 80 bar (maximum)
P2 = 63 bar ( minimum pressure; compressor setting)
P3 = 75 bar (daily minimum)
Load Cases (including those required earlier):
1. W+T1+P1(OPE) Hot operating, also Operating Case B

2. W+T2+P1(OPE) Cold operating, Operating Case C
3. WNC (SUS) Shakedown Baseline
4. W+Pl (SUS) Sustained
5. W+T2 (OPE) Operating Case A
6. W+T2+P2 ( OPE ) Operating Case D
7. W+T3+P2 (OPE ) Operating Case E
8. W+T2+P3 (OPE) Operating Case F
9. W+T3+P3 (OPE ) Operating Case G
( 10. W+T4+P1(OPE ) Operating Case H
11. L1-L3 (EXP) Expansion Hot
12. L2 -L3 (EXP) Expansion Cold
13. L1-L5 ( FAT) 40 cycles (Algebraic ) -- B- A (Summer MAX > Winter MIN)
14 . L2-L6 ( FAT) 500 cycles (Algebraic) - C-D ( Winter MAX > Winter MIN (P1-P2) )
15. L1-L7 ( FAT) 500 cycles (Algebraic) - B- E (Summer MAX > Summer MIN)
16 . L2-L8 ( FAT) 7300 cycles (Algebraic) - C-F
17. L1-L9 ( FAT) 7300 cycles (Algebraic) - B-G
18. L10-L2 (FAT) 7300 cycles (Algebraic) - H-C
Before fatigue stresses can be checked, the allowable limits must be defined in the input. Return to
the first element and click on the Fatigue Curves button at the bottom of the Auxiliary Data Area for
Allowable Stress. Fatigue data may be typed in by hand but it may also be read from data files
supplied with CAESAR II or built and stored on the hard drive. Select the 5-110-1B.FAT file to use the
steel fatigue data for B31.8.
Cycles Stress
c 1 100.000
2 10000000.0 53.000
3 100000000 . 33.400
2477.100
A
5
6
7
8
| Read from lile... |

OK Cancel
c
(
INTERGRAPH
CADWorx" & Analysis Solutions
278
Also enter in the correct temperatures and pressures as listed above, changing when the pipe is
below/above ground as necessary.
Once complete, create the load cases as described
Load Cases Stress Type Load Cycles |

L1 W+T1+P1 OPE
12 W+T2+P1 OPE
L3 WNC sus
L4 W+P1 sus
L5 W+T2 OPE
L6 W+T2+P2 OPE
L7 W+T3+P2 OPE
L8 W+T2+P3 OPE
L9 W+T3+P3 OPE
L10 W+T4 +P1 OPE
L11 L1-L3 EXP
L12 L2-L3 EXP
L13 L1-L5 FAT 40
L14 L2-L6 FAT 500
L15 L1-L7 FAT 500
L16 L2-L 8 FAT 7300
L17 L1-L9 FAT 7300
L18 L10-L2 FAT 7300
Run the analysis.
After reanalyzing the system, select all fatigue loads and the cumulative usage report to evaluate the
system loads. It is apparent that fatigue stresses and their associated cycles are quite low .
Cumulative Usage Extended

CAESAR II Ver.5.20.0, (Build 090430) Date: JUN 10, 2009 Time: 10:29
**
Job: D:\ CAE3AA DATAW52Q DATA\BURY\GA3TRAN3B E
Licensed To: COADE, INC. DEALR/EVAL COPY ID 10001
CAESAR II CUMULATIVE USAGE
Frsm Stress Allowable Usage To Stress Allowable Usage

Lead Case Cycles Node (N/rsa2 ) Cycles Ratio Node =
(N/s a2 l Cycles Ratio
CUMULATIVE USAGE EVALUATION PASSED
HIGHEST USAGE RATIO IS 0.06 AT NODE 30

MINIMUM ALLOWABLE CYCLES IS 25273
=
CASE 11 (FAT) Lll L2 L0
CASE 12 (FAT) L12*L6 L4-- 0
0
10
10
0.00
0.00
0
0
0.00
0.00
20
20
0.00
0.00
0
0
0.00
0.00
=
CASE 13 (FAT) L13 L7 L4
-
CASE 14 (FAT) L14*L5 L2
- 0
0
10
10
0.00
0.00
0
0
0.00
0.00
20
20
0.00
0.00
0
0
0.00
0.00
TOTAL: 10 0.00 20 0.00
CASE 11 (FAT) L11 L2 -L 6

* 40 20 15.99 2194132 0.00 30 265.01 25276 0.00
CASE 12 (FAT) L12 L -L4
*6 1000 20 20.96 492627072 0.00 30 104.96 511696 0.00
CASE 13 (FAT) L13=L7-L4 6000 20 15.51 703708224 0.00 30 100.80 577673 0.01
CASE 14 (FAT) L14 L5-L2
* 6000 20 49.65 7369742 0.00 30 179.34 102452 0.06
TOTAL: 20 0.00 30 0.06
CASE 11 (FAT) L11 L2-L 8

40 30 265.60 25261 0.00 40 45.56 10306356 0.00
CASE 12 (rAT) L12 L -L4
*6 1000 30 104.76 514652 0.00 40 41.99 15475465 0.00
CASE 13 (FAT) L13 L7 L4
~ B 000 30 100.60 561350 0.01 40 40.62 1 B 250100 0.00
CASE 14 (FAT) L14=LS-L2 6000 30 179.25 102607 0.06 40 30.20 79617646 0.00
| TOTAL: 30 0.06 40 0.00
1
---
; CASE 11 (FAT) L11*L2 LB 40 40 45.79 10046917 0.00 50 116.19 377261 0.00
1 CASE12 (FAT) L12*L6 L4 1000 40 40.55 18321616 0.00 50 110.30 440969 0.00
CASE 13 (FAT) L13XL7 L4 6000 40 39.22 21739600 0.00 50 107.21 460300 0.02
(
INTERGRAPH
"
Riser
Riser
v ,io
$
vit .L '
* <0
J0
r0
0
4.
$ r:
T i C -0

Y
Mi-
pV fta:
,0 ?
I

INTERGRAPH
0
Riser
280
This job is an offshore jacketed production riser. The job shows how to use the offshore capabilities
of CAESAR II. In addition to covering the hydrodynamic analysis techniques, this job also covers
model construction, element duplication, and problem resolution .
For this system, the piping details are defined in the table below
Item Diameter Thickness Temperature Pressure Fluid Marine

Growth
Riser Jacket 18 Standard 15C 0 bar 0 50mm
Product Core 6 Standard 80C 5 bar 0.85 SG 0
Injection Core 4 Standard 95C 10 bar 1.025 SG 0
The 4" injection line is used to inject water into the well to assist in product recovery. The oil is
recovered and pumped to the surface in the 6 " product line. The 18" jacket pipe is used to house the
riser tubes, offering protection and support.
This system is installed in shallow water, and subjected to a specified wave train. The objective of
the analysis is to determine the loads and stresses on the system in accordance with ASME B31.4
Chapter IX.
The wave parameters are defined in the table below:
Item Value
Height 5700mm
Period 7.72 sec
Depth 9000mm
Wave Theory Stokes 5th
Modelling
The first thing you may notice on the sketch is that the node increment in this model is 5 rather than
10 as in all the previous models. As such we will adjust the node increment for this model. This
.
change affects this model only Alternatively the configuration file can be changed if all models
should have a different node increment.
at
a DX:
DY: Node increment; 5|
? DZ: f
@1 Increment node OK Cancel
Adjust node increment

INTERGRAPH

Riser
1fMMtl
This jacketed riser will be modelled in stages, where each stage represents a continuous run of
piping from the bottom to the surface. The two core pipes ( 6" and 4" ) are enclosed in the jacket pipe
.
(18" ). The core pipes are positioned in the jacket through the use of internal spiders ( braces) In
CAESAR II, these spiders can be modelled using dummy rigid elements, connected to the jacket
through the use of CNODES.
For the 4" pipe, these dummy rigid elements must be (114.3 mm / 2 + 25 mm = 85 mm), while for
the 6" pipe, the dummies are (168.275 mm / 2 + 25 mm = 110 mm). This will provide a clearance of
50 mm between the core pipes.
When constructing a model, the first element piping spread sheet is extremely important, since
much of its data is duplicated forward throughout the job.
Injection Line
Set the parameters as follows. Note the node numbering begins at 405 - 410. The 400 series
nodes will be for the 4" line
Material: A 106 B
Diameter: 4 = 114.3 mm
Wt /Sch: S = 6.0198mm
3
Fluid Density: 1.025 SG = 1024.5 kg/m
Temp 1: 95C
Pressure 1: 10 bar
Design Code: B31.4 Chapter IX
Fac: 0.6
Fac is FI, Hoop Stress Design Factor, as per Table A402.3.5(a ) of B31.4. Appropriate
.
values are 0.72 for Pipelines or 0.60 for Platform piping and Risers
DZ = -1800mm
ANC at 405
Locate a bend at node 410. Specify a bend radius of 203 mm
Finally, we need to reset the elevation of the system, so that node 405 lies on the sea
bottom. (This is important for the wave and wind loading later. While wave loading allows a
relative definition of position of the piping in the water, wind does not. Therefore, zero
elevation must be properly specified on the system so that the correct wind loads
calculated.) Use the global coordinate button to reset the origin, node 405, from (0,0,0) to
( (0,-9000,0).
Enter Global Coordinates (mm.) for Node 405
x 10.000 | Y: -9000.000 Z: iM
OK | | Cancel
(
INTERGRAPH
0
Riser
282
Continue to the next element - 410 -415
This is 1500mm in the Y direction, and has two restraints at node 415, an X and a Z. Both the
.
restraints will have a CNODE to 414 Node 414 will be the spider connection as discussed above .
Node 415 CNode: 414
Type X T Gap
Stil Mu
Node 415 CNode 414
Type Z Gap
Stil; Mu
Continue to the next element. As the isometric shows, the riser continues in 1500mm sections, right
the way up to node 470 at the top. We can create this all in one element, and break to split up into
.
the 1500mm sections Change the node numbers to 415 - 470. The pipe travels 16500mm in the Y
direction overall .

From 415
Name
To 470

DX.
DY 16500 000 mm
DZ
Offsets
Now we can break this element with a node increment of 5. Use the break command as before, but
this time, select the Insert Multiple Nodes radio button.
Classic Pip ng Input

0
W From: 415
To: 470
Break
Break current element

INTERGRAPH
Riser
283
iTwil uJTiuJi
Insert Single Node

o Insert Multiple Nodes

Mew Mode Murnl
Distance () from Node 5

in (mm.) from Mode 470
Total Number of Break Elements 11
Node Step 5|
Length of each element 1500 000 mm
Allow Duplicate Node Numbers Q
OK Cancel
Enter in a node step of 5 - the Total Number and Length fields will be calculated automatically. Also
specify the support configuration as at node 415.
Checking the system coordinates in the list processor shows that node 440 is at the surface
(elevation 0), and there are 12 vertical elements - 6 above the surface and 6 below the surface .

INTERGRAPH
*
Riser
284
Coordinates 9 x
Element X Y Z
Nodes Coordin Coordinate Coordinate
From 405 0.000 m -9000.000 mm 0 000 mm
To 410 0.000 m -9000.000 mm -1800 000 mm
From 410 0.000 m - 9000.000 mm -1800 000 mm
To 415 0.000 m -7500.000 mm -1800 000 mm
From 415 0.000 m -7500.000 mm -1800 000 mm
To 420 0.000 m -6000 000 mm -1800 000 mm
From 420 0.000 m -6000 000 mm -1800 000 mm
To 425 0.000 m 4500 000 mm -1800 000 mm
From 425 0.000 m 4500 000 mm -1800 000 mm
To 430 0.000 m -3000 000 mm - 1800 000 mm
From 430 0.000 m -3000 000 mm -1800 000 mm
To 435 0.000 m - 1500 000 mm -1800 000 mm
From 435 0.000 m - 1500 000 mm -1800 000 mm
To 440 0.000 m 0.000 mm -1800 000 mm
From 440 0.000 m 0.000 mm 1800 000 mm
To 445 0.000 m 1500.000 mm -1800 000 mm
From 445 0 000 m 1500 000 mm -1800 000 mm
To 450 0 000 m 3000 000 mm -1800 000 mm
From 450 0 000 m 3000 000 mm -1800 000 mm
To 455 0 000 m 4500 000 mm -1800 000 mm
From 455 0 000 m 4500 000 mm -1800 000 mm
To 460 0 000 m 6000 000 mm -1800 000 mm
From 460 0 000 m 6000 000 mm -1800 000 mm
To 465 0 000 m 7500 000 mm -1800 000 mm
From 465 0 000 m 7500 000 mm -1800 000 mm
To 470 0 000 m 9000 000 mm -1800 000 mm
Add a bend at node 470 and change the radius to 203mm as before.
Complete the riser by adding in the final element (470 - 475 ). This is 1500mm in the -Z direction
and an anchor is located at node 475.
The injection line is now complete .

INTERGRAPH

Riser
Product Line
For the product line, duplicate the injection line, this is essentially duplicating the entire model at
this point. This duplication will use a node increment of 200, followed by a modification to the
temperature, pressure, diameter, thickness, and fluid specific gravity .
Select the entire model and duplicate as follows:
Block Duplicate
Options
a Identical
Mirror Y-Z
Setup
MirrorX-Z
MirrorX-Y
Insert Copied Block.
At End ol Input
Node Increment: 200 ]

Smallest Node Inside Block 405
Largest Node Inside Block: 475
Smallest Node Outside Block 0
Largest Node Outside Block 0
OK j | Cancel
Change the properties of element 605-610 so that they are correct for the 6 line:
Diameter: 6 Wt/Sch: STD

Tl: 80C PI: 5 bar
Fluid Density : 0.85SG

INTERGRAPH
'
Riser
286
Jacket
Important Notes When Duplicating Core / Jacket Piping
The diameter is changed after the duplication.
Typically, the core pipe uses long radius elbows, and the jacket uses short radius elbows .
This allows the radii of both the core and the jacket to be the same .
If the jacket contains fluid, Its density must be computed such that the unit weight across the
entire jacket Inner diameter yields the same weight as the real fluid in the annulus between
the jacket and core pipes.
Core pipes do not see environmental loads. This is important to check after building the
model .
Continue after the last element (670-675) and change the node numbers again. This time for the
18 pipe - so use node numbers 1810 to 1870 .
This element is 18000mm long
Diameter: 18
Tl: 15C
PI zero
Fluid density: zero
Restraints: X
Y
Z
RY
Marine Growth:50mm
CH Forces /Moments Wind

Uniform Loads o Wave
J Wind / Wave
OH
(
Drag Coef Cd
Added Mass Coef Ca.
Lift Coefficient Cl
f Marine Growth 50.000
Marine Growth Density:
Next break this element, using the multiple break function again, and a node increment of 5. This
will split the element into 12 sections, each 1500mm in length.

INTERGRAPH0
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287
.
At node 1870, define a GUIDE restraint With this element vertical, the program will create an X and
a Z restraint at node 1870.
The Wind/Wave settings will propgate through the model until changed or turned off, even though
on subsequent elements will not have the Wind/ Wave check box ticked .
On element 1840-1845 (the first pipe out of the water and a t zero elevation), turn off the wave and
set a wind shape factor of 0.65. This is a typical value for cylindrical bodies .
The model at this point shows the three lines, but they are not properly located in space. A series of
construction elements will place these lines properly in space and also provide the right structural
connectivity. The idea here is to run a dummy rigid element from the restraint CNODEs of the
injection line, to the nodes on the jacket and, on to the restraint CNODEs of the product line.
Navigate to the end of the model and define a new element from 414 to 1815. This element will be
85mm long in the X direction, and will connect the restraint at 415 (with CNODE 414) to the jacket at
1815. Define this as a rigid element with zero weight.
From 414 El Bend

Name 0 Rigid
To: 1815
[ I Expansion Joint
'
DX 85.000 mm Restraints
[ Hangers
DY:
f Nozzle Rex.
DZ:
Forces/Moments
Offsets
Pi I Inifnrm I narls
Turn off the wind.
Lii niyiu _
i j oti a Or i eea V
Expansion Joint | Wind
Restraints E Displacements
| Wave
a Off
Hangers Flange Checks >
Nozzle Flex. Nozzle Lmt Check
Wind Shape Factor.
Forces/Moments
Added Mass Coef Ca:
[ Wind / Wave 1 Lift Coefficient Cl: f

Material: | (106)A106 B Marine Growth:
Allowable Stress Marine Growth Density:
Elastic Modulus (C): 2 0339 E+ 008
Follow with another dummy rigid element from 1815 to 614; 110 mm in X. This will join the product
line through the restraint at 615 with its CNODE at 614.
The graphics should now display the model correct.

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"
Riser
Using the Elements listing, duplicate these last two elements, with a node increment of 5 to place
the spider on the next restraint. Continue this duplication so that the spiders are placed all the way
up the riser.
Once complete, and all restraints along the riser are defined, run the error checker.
There will be a number of warnings concerning " zero weight " rigid elements and "four elements
framing into a node". These are all acceptable in this instance.
Note that the Centre of Gravity Report shows a combined weight of about 33,000 N. Recall that the
.
riser is supported only at its base, with a pin connection In reality, risers are supported by top-side
tensioners, exerting a force sufficient to ensure the riser is always in tension. For this job, return to
the input and at node 1870 (the top of the riser), define a hanger to apply a constant vertical force of
45,000 N.
Re-run the error checker . The model should now be ready for analysis.
ft
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289
Hydrodynamic Theory
A basic discussion of hydrodynamic theory can be found in the CAESAR II documentation (Technical
Reference Guide, Chapter 6). There are a variety of different wave theories, used to compute the
water particle velocities and accelerations resulting from a wave train. CAESAR II includes solutions
to the three most commonly used wave theories; Airy, Stokes 5th, and Stream Function. The latter
two theories are non-linear, but provide a better description of the water particle behaviour.
CAESAR II also includes modified versions of these three theories, which allow consideration of the
fluid above the mean sea level.
The basic procedure is to solve forthe wave length, based on a selected wave theory. Once the wave
length is known, the velocities and accelerations can be determined at any position in the water
column. Based on these values, drag ( Cd ), inertia (Cm), and lift ( Cl ) coefficients are determined for
each pipe element. These coefficients, along with the velocity and acceleration are used to compute
the force applied to the piping elements, using Morrison's equation:
(
F= xpx Cd x. D x U x \ U \ + x p x. CmxD 2 xA
Where:
p = fluid density
Cd = drag coefficient
D = pipe diameter
U = particle velocity
Cm = inertial coefficient
A = particle acceleration
The particle velocities and accelerations are vector quantities which include the effects of any
applied waves or currents. In addition to the force imposed by Morrison's equation, piping elements
.
are also subjected to a lift force and a buoyancy force The lift force is defined as the force acting
normal to the plane formed by the velocity vector and the element's axis. The lift force is defined as:
1
Ft = x p x Ci X D X U2
Where:
( p = fluid density
Ct = lift coefficient
D = pipe diameter
U = particle velocity
The buoyancy force acts upward, and is equal to the weight of the fluid volume displaced by the
.
element Once the force on a particular element is available, it is placed in the system load vector
just as any other load is. A standard finite element solution is performed on the system of equations
which describe the piping system .
For this particular model, a sample hand computation will be used to estimate the applied wave
load. This will be used as a verification of the loading, to ensure we are making the correct
assumptions and modelling correctly .
(
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290
B 31.4 Code Requirements

The B31.4 piping code includes Chapter IX, for " Offshore Liquid Pipeline Systems". The scope of this
chapter states: " For the purposes of this Chapter, offshore pipeline systems include offshore liquid
pipelines, pipeline risers, offshore liquid pumping stations, pipeline appurtenances, pipe supports,
connectors, and other components as addressed specifically in the Code."
In Section A401.10.1, this Code states: " All parts of the offshore pipeline system shall be designed for
the most critical combinations of operational and environmental loads, acting concurrently, to which
the system may be subjected." This means that operating loads are to be combined with wind, wave,
and currentl
In Section A402, this Code states that:
- Hoop Stress is limited as defined by: Sh F1 x Sy
Note that the pressure term used in the hoop stress equation is the difference between
internal and external pressure.
- Longitudinal Stress is limited as defined by: SL F2 x Sy
The longitudinal stress is defined as the axial stress plus or minus the bending stress,
whichever results in the larger stress value.
- Combined Stress is limited as defined by : Scomj ,< F3 x Sy
Here, SCOmb is defined by the Tresca Combined Stress Equation.
.
To satisfy these requirements, a single load case can be defined This load case should include all
loads defined in the input (weight, pressure, temperature, wave, wind, etc). CAESAR II will compute
the above stresses for each element and report the maximum stress value with its corresponding
allowable. The factors FI, F2, and F3 are defined in the code in Table A402.3.5 (a) as:
Location Hoop FI Longitudinal F2 Combined F3

Pipeline 0.72 0.80 0.90
Riser 0.60 0.80 0.90
The B31.4 piping code states that the environmental loads used in the analysis correspond to the
"100 year" storm. This is equivalent to the largest storm that occurs every 100 years.
(
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291
Hydrodynamic Input
The hydrodynamic input specification in CAESAR II is relatively simple. Up to four different loading
conditions can be defined. These different conditions could be different waves, currents, or
directions. For each of these loading conditions the data is defined as shown below
File
Static Analysis [D:\TRAINING\CAFSARII\RI
Edit
' iffltnQiJtm
lias Iff & hi .
Load Cose Editor |Load Cose Options j WindLoads Wove Loads
Phase Data
Editing Wove Cose 1 Of 4 | Copy Wave Vector |
' Same Phase at all Elements
Current Data Phase Angle 0 0
Current Profile Type I* 0 Phase Specified at Origin
Surface Velocity
Sea Water Data
Direction cosines -X: Z Free Surface Elevation: Q . OOO
Wove Data Kinematic Viscosity: 1.1900

Wove Theoiy Stokes 5th I Density USE
Stream Function Order h] Current Table
Water Depth Depth Velocity Depth Velocity
1 6
Wove Height ;
5 70
2 7
Wave Period 7 72
3 8
Wove Kinematics Factor 1 000
4 9
Direction cosines -X. Z 1.0000 5 10
This particular load definition is specifies only a wave. However, either a standard current profile or
a current table can also be defined. The particular wave used in this example is a well-publicised
wave, used as the example in the paper by Skjelbreia and Hendricson for the solution to Stokes 5th
Order Gravity Waves. Note this does not correspond to a "100 year storm". This wave is being used
because it has published results.
The wave data consists of the water depth (9 m), the wave height (5.7 m), the wave period (7.72
seconds ). The wave kinematics factor is a factor used for Stream Function and Stokes 5th solutions
to account for the spreading of the wave energy in a real sea state Values typically range from 0.85 .
to 1.0, and serve to reduce the particle velocities .
The "Phase Data" defines how the wave is imposed on the piping system. Since the wave moves over
the piping system, every element of the system is exposed to every phase of the wave. At one
particular position (phase) of the wave the piping system will experience the maximum
environmental load. Performing 360 solutions to find this maximum is not practical, given the other
factors involved (combination with current, non-uniform sea state, directionality, and spreading).
Typically drag governs the loading on (small) piping system, so the wave is positioned so that most of
the piping system sees a zero phase angle. Alternatively, the input can be set so that the entire
system sees a zero phase angle.

(
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292
Wave Solution
The hydrodynamic parameters as defined in the input are used by the Stokes 5th wave theory to
determine the water particle data. This solution can be evaluated numerically (by reviewing data
tables) or graphically ( through the use of plots). A brief evaluation is shown below.
First, two dimensionless parameters are computed and used to determine the "suggested" wave
.
theory This evaluation is performed by plotting these dimensionless parameters on a chart, found in
.
a number of publications This chart, with the location of the specified wave for this job is shown in
.
the figure below This chart (and the remainder of the wave solution) can be obtained using the
Chart Current Results button on the Load Case Editor .
1 Static Analysis - [D:\TRAINING\CAESARTARISER]
j File Edit
=0 M.
%
Load Case Editor i Load Chart Current Results frads Wave Loads
(
AoDlicable Wave Theory
Chart Selection
Applicable Wave Theory *
Information
0 01 STREAM 9TH ORDER
Water Depth 0 iiuon
Wave Height 5 7000

? 0 001
Wave Period: 7 7200
Current Profile Type <Noe Specked> D 0001
Wave Theory:
1e-5
Wave Length. 732890 0.0001 0.001 0 01
d/gTA2
Max Surface Elevation: 00000
- Stream 3
- Stream 5
- Stream 7
l <
* View Data Table Clrnom O
th
For this particular wave, the chart shows that the recommended wave theory is Stream Function 9
Order. (This job will still employ the Stokes 5th solution, for illustrative purposes.) Each region of the
chart corresponds to a different wave theory, as detailed in the key at the bottom.
The Drop down list at the top of the dialog box allows other graph representations to be shown.
Select the "Surface Elevation vs Phase" option

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293
Chart Selection
.
EElicoble Wnve Theo a
Applicable Wave Theory
Horizontal (X) Velocily vs. Depth @ 0 phase
Horizontal (2) Velocity vs. Depth @ 0 phase
Acceleration (Y) vs Depth @ 0 phase
.
Surface Elevatian vs. pharos
Horizontal (X) Velocity vs. PJiase @ 0 depth
Horizontal (Z) Velocity vs. Phase @ 0 depth
Horizontal (X) Acceleration vs . Phase @ 0 depth
Horizontal (Z) Acceleration vs . Phase 0 depth
Wm/O Period
This results in the following graph.
Surface Elevation vs. phase
4.5 -
4-
3.5 -
3-
2.5 -
-
E
2-
1.5 -
n
-
iD
0.5
0-
-0.5 -
-1 -
-1.5 -
( -2
0 20 100 140 180 220 260 300 340
Phase (deg)
This figure shows that the wave crest is at a phase of zero, with the trough at a phase of 180
.
degrees, as expected Notice also that the wave profile is not symmetric about the mean water level.
For this 5.7 m wave, the crest is 4 m above the still water level while the trough is 1.5 m below the
.
still water level Only the Airy wave theory produces a symmetric wave profile.

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294
Changing the plot to "Horizontal Velocity versus Depth at Zero Phase" results in the figure shown
below. This figure shows that the velocity decreases with depth, as expected. Note however that
there is still an appreciable velocity, even at the bottom for this particular wave.
Chart Selection
I urface Elevation vs phase
Applicable Wave Theory
Horizontal (X) Velocity vs. Depth @ 0 phase
IHorizontalf (Z) Velocity vs. Depth ]0[phas
Acceleration (Y) vs Depth @ 0 phase
Surface Elevation vs phase
Horizontal (X) Velocity vs. Phase @ 0 depth
Horizontal (Z) Velocity vs. Phase @ 0 depth
Horizontal (X) Acceleration vs . Phase @ 0 depth
Horizontal fZ) Acceleration vs. Phase 0 depth
Horizontal ( 2 ) Velocity vs. Depth (. 0 phase
-1 -
-2 -
-3 -
-4 -
.E -5 -
a.
-6 -
-7 -
-8 -
-9 -
-10
0 0.4 0.8 1.2 1.6 2 2.4 2.8 3.2 3.6
Velocity (m. //sec)

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295
Selecting the plot "Horizontal Velocity versus Phase at Zero Depth" results in the figure below. This
figure shows that velocities are positive in the wave crest, and negative in the wave trough, again as
expected. This is why there is a mean mass transport in the direction of the wave train.
Chart Selection
.
Velocity vs. Phase lOfcJeptH F
Applicable Wave Theoiy
Horizontal pq Velocity vs Depth 0 phase
Horizontal (Z) Velocity vs Depth 0 phase
Acceleration (V) vs Depth 0 phase
Surface Elevation vs. phase
Horizontal (X) Velocity vs Phase 0 depth
Horizontal (X) Acceleration vs Phase 0 depth

Horizontal (Z) Acceleration vs Phase 0 depth
Horizontal (Z) Velocity vs. Phase (. 0 depth
3.8
3.6
3.4
3.2
3
2.8
2.6
2.4
" 2.2
if
2
E
1.8
a 1.6
> 1.4
1.2
0.8
0.6
0.4
0.2
0
0 20 100 140 180 220 260 300 340
Phase (deg)
Note that in this plot, the velocity in the trough is shown as zero. This is because the plot is showing
the data at a depth of zero, the still water level. In the trough region, the water is below this level. At
a lower depth, the velocities do go negative, which can be seen by reviewing the actual data tables.

(
INTERGRAPH
"
CADWore & Analysis Solutions
Riser
Selecting the plot "Horizontal Acceleration versus Phase at Zero Depth" results in the figure below.
This figure shows that the water particles are accelerating in front of the wave crest, and
decelerating behind the wave crest. Again, in the trough area, the plot shows values of zero because
the water level is below the " zero" elevation.
Horizontal fZ) Acceleration vs Phase 0 depth
Chart Selection 4
35
3
2.5
Water Depth 9.QUOO 2
Wave Height
Wave Period:
. 7000
7 7200
?5 0.51
15
_
C
E
0
Current Profile Type: cNone Speohecl>
-0.5
Wave Theory: Store's 5th -1
< 1.5
-
-2
Wave Length: 73 2890
-2.5
Mox Surface Elevation 3 0000 -3

-3.5
-4
20 100 140 180 220 260 300 340
OK View Data Table Phase (deg)
Plots such as these are typical of wave solutions. The wave solution produces data for the entire
water depth over the entire wave phase. Horizontal and vertical velocities and accelerations can be
studied as a function of depth or phase. In addition to plotting the data, the actual numerical values
can be reviewed by clicking the View Data Table button. This file is called <jobname>.WVl and is a
text file - so opens in Notepad.
Q BaRWVt NetrpJd
.
<M FonMt
* f
3gur J
7|
0.01339
ES ; is
M / QT
*2 0.009 *4
Broking t
- inlt
Bee 01eniled -
wave Tlieory per Vl ult Fig I 3 1 3 STREAM FUNCTION
KWasffi ns
7
assr J:8 .ii :i; 3iH : .

3 Si 3 IB 2.75
n in. H as
2 30
Horizontal Partlcal Velocity (x)
I B4 l 0
- Including Current
3.01
IP
ii
II
l
! III !I si ii 1 in II
i
Horizontal Partlcal velocity ( Z) - Including Current

1 is
s is
8 i- S
a il 11111 11 11 SI
-1
(
INI tKbKAPH
*
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297
At the top of this file, the wave length and speed are reported. (The corresponding values from
Skjelbreia and Hendricson' s paper are 76.2 m (250.0 ft) and 9.87 m/sec ( 32.39 ft/sec). The difference
here is due to a correction to the Stokes solution published in 1985.) This set of tables shows the
free surface as a function of phase angle. If the water depth (9 m) is added to these values, the result
is the row of values labelled "Surface Elevation ". The "Horizontal Velocity" table (for the Z direction)
is also shown. The first row ( zero depth) and first column ( zero phase) were used to produce the
velocity plots shown above.
Hydrodynamic Coefficients
The water particle data can be used directly in Morrison's equation to determine the force acting on
the pipe elements. However, in order to employ Morrison's equation, several hydrodynamic
coefficients must be determined. These coefficients are a function of the Reynold's and Keulegan-
Carpenter numbers, and are typically presented in graphical form, as shown in the figure below .
These coefficients have been determined through testing.
Cd versus Re and K C| versus Re and K
The Keulegan-Carpenter Number, K, is defined as

T
C Where:
Um = maximum fluid particle velocity
T = wave period
D = characteristic diameter of the element
The Reynolds number Re is defined as

D
Re ~ Um * ~
Where
Um = maximum fluid particle velocity
D = characteristic diameter of the element
v = kinematic viscosity of the fluid (1.17 mm2/sec for sea water).
C
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298
Note that these parameters depend on the water particle velocity as well as the diameter of the pipe
element. Therefore, these parameters typically vary over the piping model. For this reason, it is best
to leave the entry for these coefficients blank in the input. This will allow CAESAR II to determine the
coefficients on an element by element basis during the solution phase of the job.
A rough hand computation should be made to ensure that the applied environmental loads are as
expected. To assist in this check, a stand -alone load case with only wave loading will be setup to
check against these hand computations. The hand computations are shown below.
Wave Solution Data
Elevation Velocity Elevations are measured from the sea bottom

(m) ( m /sec )
0 2.3 All data for a phase angle of 0.0
1.5 2.370
3 2.440
4.5 2.615
6 2.870
7.5 3.235
9 3.710
Hydrodynamic Coefficient Computation
Node Elevation Velocity Acceleration Keulegan - Reynolds Cd Cm Cl

(m) ( mm /sec ) ( m/ sec2 ) Carpenter Number
Number
1810 0 2300 0.00 31.87 1.08 E +6 0.661 1.746 0.257
1815 1.5 2370 0.00 32.84 1.11 E +6 0.656 1.749 0.250
1820 3 2440 0.00 33.81 1.14 E +6 0.651 1.751 0.243
1825 4.5 2615 0.00 36.23 1.22 E +6 0.639 1.759 0.226
1830 6 2870 0.00 39.76 1.34 E + 6 0.621 1.769 0.202
1835 7.5 3235 0.00 44.82 1.51 E + 6 0.625 1.765 0.200
1840 9 3710 0.00 51.40 1.74 E + 6 0.631 1.759 0.200
Element Force Computation
Element Avg. Avg. Cd Avg. Cl Diameter Density Drag Lift Force

Velocity ( mm ) ( kg/cm 3 ) Force ( Fd ) ( FI )
( m /sec ) ( N / mm ) ( N / mm )
1810-1815 2.335 0.658 0.254 557.2 0.001025 1.025 0.395
1815-1820 2.405 0.653 0.247 557.2 0.001025 1.079 0.408
1820-1825 2.528 0.645 0.235 557.2 0.001025 1.176 0.428
1825-1830 2.743 0.630 0.214 557.2 0.001025 1.353 0.460
1830-1835 3.053 0.623 0.201 557.2 0.001025 1.658 0.534
1835-1840 3.473 0.628 0.200 557.2 0.001025 2.163 0.689
Fd = 0.5 x density x D x Cd x V x abs (K) FI = 0.5 x density x f l x C I x F x V

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299
Element Length Fd FI
Total Drag force = 12681.40 N
( mm) (N) (N)
1810-1815 1500.00 1537.29 592.13
Total Lift Force = 4370.25 N
1815-1820 1500.00 1618.83 611.34
1820-1825 1500.00 1764.72 642.70
1825-1830 1500.00 2029.74 689.51
-
1830 1835 1500.00 2468.55 801.55
1835-1840 1500.00 3244.27 1033.02
Notice for these computations, that " average " values are being used for the element velocities and
hydrodynamic coefficients. The CAESAR II program actually computes the exact values at integration
points on each element, from which the "fixed end forces and moments" are determined.
Wind Loading
.
The default ASCE 95 wind loading procedures will be used on this riser (This standard states that the
minimum wind pressure is 10 Ib/sq.ft. or 0.479 KN/ sq.m.) The basic procedure to compute the wind
load on each pipe element is as follows:
.
Obtain the wind speed (V) From ASCE 95, the Gulf Coast of the U.S. can experience winds of up to
.
225 km/hr (140 m/hr) API-RP2A recommends a wind velocity of 175 km/hr (109 m/ hr) for the Gulf
.
of Mexico Assume a wind speed of 55m/ sec (123 m/hr ) for this job.
Determine the applicable structural category from ASCE 95, Table 1.1. From this table, select
category II (2).
Determine the Importance Factor (I) from ASCE 95, Table 6.2. Based on the selected category, the
Importance factor is 1.0.
..
Determine the Exposure Category from ASCE 95, Section 6.5 3 For this job, select exposure category
D (flat, unobstructed terrain).
From ASCE 95, Commentary Section 6.5, determine Kz. This term varies by elevation and therefore
.
may vary from element to element Constants used in the equations to determine Kz can be
obtained from Table C6-2, based on the exposure category .
Determine Kzt, which is the wind speed-up over hills. For this job, there are no hills, so Kzt is 1.0.
Based on these parameters, compute the velocity pressure as defined in ASCE 95, Section 6.5 1. .
This is: qz = 0.613 * Kz * Kzt * V2 * I, where all terms are defined above. For this equation, V is
expressed in meters per second and qz in newton per square meter. (If V is in mph and qz in Ibf/ft2,
the constant becomes 0.00256.)
Once qz is known, the force on the element can be determined from: F = qz * Gf * Cf * A, where:
- Gf is the gust response factor
- Cf is the shape factor for the element (defined in the piping input)
- A is the projected wind area of the element (including insulation if specified)

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I 300
The gust response factor Gf can be determined analytically as defined in the ASCE Commentary.
However, this procedure requires the first natural frequency of the piping system, which can be
obtained through a modal analysis. This dynamic procedure is not addressed in this seminar If the .
natural frequency input is left blank, CAESAR II will use a gust response factor of 0.85 as defined in
ASCE 95, Section 6.6.1 .
For this system, the wind load can be defined for the analysis as shown below.
!Q &
Load Case Editor Load Case 0 tions Wind Loads Wave Loads
ASCE# 7 Wind Load Parameters

Editing Wind Cose [ f t j]ol
. | ( Copy Wind Vectw 55.000
Basic Wind Speed m / sec
Select Wind Code or Profile A
Wind Exposure (2, 3. or 4)
ASCE# 7 2005 r
.
-
Structural Damping Coef. (Typ 0.03)
.
Structural Classification (1 Z 3 or 4)
0030
2
(or) Importance Factor 1 000
Structure Natural Frequency ( Hz ) 0 000

Wind Direction Specification
0 0000 ASCE#7 Topographic Fedor Parameters
X Wind Direction cosine (or vector) 00000
Height of Hill or Escarpment m
Crest Distance m 00000
V Wind Direction cosine (or vector) 0 0000
Distance from Crest to Site m 0.0000

Z Wind Direction cosine (or vector) 1 0000
Hill Type (0 1. Z or 3) SI
User Wind Piolile
(z
(
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301
For this system, the applied wind loads can be approximated as shown below.
Wind Solution Data ( per ASCE 7)

Element Mid- Point Alpha Zg 2/alp 4.6/ zg z / zg (.xzg )( 2 / alvha) Kz
elevation (m ) ha
M(m) t
1840-1845 0.75 11.50 213.36 0.174 0.0216 0.513 1.031

1845-1850 2.25 11.50 213.36 0.174 0.0216 0.513 1.031
1850- 1855 3.75 11.50 213.36 0.174 0.0216 0.513 1.031
1855-1860 5.25 11.50 213.36 0.174 0.0246 0.525 1.055
1860-1865 6.75 11.50 213.36 0.174 0.0316 0.548 1.102
1865-1870 8.25 11.50 213.36 0.174 0.0387 0.568 1.142
(2 / alpha )
( Kz 2.01 x
where x = max ( 4.6 or z)
Velocity Pressures
Element
1840-1845
wm
1.031
V (m/ s )
55
1
1
qz
1912 qz = 0.613 x Kz x Kzt x I x V 2
1845-1850 1.031 55 1 1912
1850-1855 1.031 55 1 1912 Kzt = 1.0
1855-1860 1.055 55 1 1957
1860-1865 1.102 55 1 2044
1865-1870 1.142 55 1 2117
Wind Force
2
Element qz G Cf Af (m ) Force (N)
1840-1845 1912 0.85 0.65 0.686 725
1845-1850 1912 0.85 0.65 0.686 725 Force = qz x C x Cf x Af
1850-1855 1912 0.85 0.65 0.686 725
1855-1860 1957 0.85 0.65 0.686 741
1860- 1865 2044 0.85 0.65 0.686 775
1865-1870 2117 0.85 0.65 0.686 802
Total Applied Force = 4492 N
(
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302
Load Case Setup

The load cases required are as below :
We require for our code stress check, an operating case for each wind and wave direction In this .
case we have a Z direction wind load and wave load Therefore we will create cases for operating
conditions PLUS the wind and wave loads and MINUS the wind and wave loads
Hr Load Cose Editor [ Load Case Options | Wind Loads | Wave Loads j
Loads Defined in Input Load Cases Stress Type Recommend

W - Weight L1 W+T1+P1+H OPE
T1 - Thermal Case # L2 WW 1 OCC
Load Cycles
-
P1 Pressure Case #l L3 Wll'IT OCC
-
H HangerLoads L4
L5
L1+L2+L3
L1-L2-L3
OCC
OCC
WIN1 - Wind Load Case #1 | Import Load Cases |
W1N2- Wind Load Case # 2
-
WIN3 Wind LoadCase # 3
These load cases can be given more meaningful names in the Load Case options tab
Load Case Editor Load Case Options wind Loads Wave Loads
Output Output Comb Snul

Load Case Name Status Method Act
Type
L1 Standard Operating Keep Disp/Force/Stress

L2 Wave Component Keep Disp/Force 0
L3 Wind Component Keep Disp/Force 0
L4 OPE+Wind and Wave (+Z) Keep Disp/Force/Stress Algebraic .
LS OPE + Wind and Wave (-Z) Keep Disp/Force/Stress Algebraic
The results for all load cases will be available at the output level, but for the "environmental only "
load cases, only displacements and forces will be presented by the output processor. Load cases # 4
and # 5 are the Code compliance cases necessary for the stress check. The output status for load case
#1 could have been set to "discard", since in this instance its results are not significant on their own.
However, it may be necessary to evaluate the results of this load case in the event of overloads or
over stressed elements. Therefore the output status is left as " keep" ) .

c
INTERGRAPH 0
Riser
303
Analysis
Once the load cases are defined (and the loading data has been checked), the analysis can proceed
as usual. At the output level, the results of the " environmental" load cases should be reviewed to
ensure they agree with the hand computations. For this job, the environmental loads act on the riser
body and are resolved about nodes 1810 and 1870. The restraint summary report details this loading
resolution.
Restraint Summary ? X
CAESAR II 2011 SP1 Ver.5.30.01, (Build 110220) Date: AUG 24, 2011 Tine: 12:7
Job: D:\TRAINING\CAESAR 1I\RISER
Various Load Cases
Load Case N. N. N . N.m. N.n. N.n.
3(OCC) -0 0 - 664 0 0 0
MAX -211/L2 -1341/L2
675 Rigid ANC

2(OCC) 299 #39 1145 -1073 397 467
3(OCC) 0 -27 509 -533 -0 0
MAX 299/L2 439/L2 1145/L2 -1873/L2 397/L2 467/L2
1 B 10 Rigid X; Rigid Y; Rigid Z; Rigid RY

2(OCC) 2769 0- 6749 0 234 0
3(OCC) - 0 0- 631 0 77 0
MAX 2769/L2 -
0/L2 6749/L2 234/L2
1070 Rigid GUI; Rigid GUI; User Design CSK

2(OCC) 010 0 2030 0 0 0 n
3(OCC)
MAX
- 0
01O/L2
0 2620
2620/L3
0 0 0
For load cases # 2 and #3, summing the FZ loads at nodes 405, 475, 605, 675, 1810 and 1870 yields
the applied environmental loads. These loads are summarised in the table below.
Applied Load Summation (from CAESAR II )
Node Wave Wind

Drag Fz ( N ) Lift Fx (N ) Fz (N )
405 539 78 105
475 380 85 200
605 1697 287 347
675 1145 299 589
1810 6749 2769 631
1870 2030 810 2620
Total Load: 12540 4328 4492
These loads can be compared to the hand computed results of 12681 N, 4370 N , and 4492 N. This is
an acceptable comparison, given the approximations made in the hand computations .

INTERGRAPH

Riser
304
The code compliance report shows that there is a failure in one of the operating cases. This is
.
located around the bottom of the riser on the elbow Reviewing the Stress Report shows that the
bending stress is dominating the behaviour of the system at these points .
Axial Stress: 3.B 6 Node 1910
Bending Stress: 202.3 BKode 409
Torsion Stress: 1.9 SNode 600
Hoop stress: 9.5 SNode 40B
3D Max Intensity: 211.0eNode 409
405
409
1.93
1.93
169.14
72.05
-
1.32
1.32
9.4
9.49
176.73
79.66
1.000
1.000
1.000
1.000
171.07
73.97
193.05
193.05
09.61
30.32
--
B31.4 IX
B31.4 IX
400
-
109
1.93
0.03
103.23
-
202.3 1
-
1.32
0.90
9.4
9.49
190.02
211.91
2.543
2.543
2.119
2.119
105.16
202.37
193.05
193.05
95 91
104. B 3
-
B31.4 IX
-
331.4 IX
409
410
0.03
0.49
202.34
197.90
-
0.50
0.11
9.44
9.49
211.31
207.00
2.543
2.543
2.119
2.119
202.37
190.4c
193.05
193.05
104.03
102.00
331.4
--:
X
331.4 .X
One solution here is to reduce the thermal component of the stress by extending the bottom-side
piping, from 1800 mm to 3000 mm. This drops the stress level to 86.5% of the allowable.
.
(This job is not intended to be an example of good riser design The riser tension was arbitrarily
.
selected to be simply larger than the "air weight" of the riser Additional vertical supports may be
used along the length of the riser to assist in supporting the core piping. For larger (longer) risers,
external buoyancy chambers are used to offer additional vertical support along the riser body. None
of these concepts are addressed in this example.)
(Fatigue has not been addressed in this example, but is typically a required consideration. For this
job, the fatigue (FAT ) case would be defined as " L4-L5" with a specified number of cycles and a
corresponding material fatigue curve.)
(
INTERGRAPH
'
SUPT01- Water Hammer
305
SUPT01 - Water Hammer
SUPT01 PIPE -
12 DIA STD SCH
MAT L - -
A 106 GR 0
FLUID - WATER
PRESSURE -
10.5 BAR
TEMP -
175 DEGREES C
ELBOWS - LONG RADIUS
INSULATION
VALVES
- 50 mm CS
150 /! GATE VALVES (3675 N)
40
36
NOZZLES ( ANCHOR POINTS) @ 10 & 90
THERMAL CYCLES < 7000
( 20
22 34
(
30
80
85
90
46
72
70
50
55
(
v
INTERGRAPH
*
306
This exercise introduces the Occasional stress evaluation in B31.3. We will return to the model
produced previously SUPT01 and simulate a fluid hammer event acting when the valve slams shut .
This force will be applied to the model and defined as a shock load case and evaluated according to
the Occasional stress requirements of B31.3.
For Occasional stress evaluation, B31.3 requires:
.
Long. Sustained Stresses + Long Occasional Stresses < k Sh, where k = 1.33
In CAESAR II, this equates to a SCALAR summation of the SUS case with the OCC case, using the OCC
stress type.
Note: The OCC stress type serves two purposes: (1) it directs that stresses be calculated according to
. .
the occasional equation , and ( 2) it activates (i e., locks) any snubbers in the model
/
Edit the Model I
..
Open the file created previously SUPT01. Using File > Save As. create a new file called SUPT01 fluid
Hammer.c2
There are some slight changes to the support configuration in this file compared to our analysis done
previously.
Edit the support configuration as shown in the isometric sketch, and as detailed below.
Element 20-30
o Break this element
o Create a new node number 22, located 1400mm from node 20.
o Add a +Y restraint at node 22
Element 30-33
o Change the to node from 33 to 34
o Edit the length of this element and change to 6000mm
o Add a +Y restraint at node 34
Element 33-37
o Change the "from node from 33 to 34 (
o Change the to node from 37 to 36
o Edit the length of this element to be 6000mm
o Remove the +Y restraint
o Add a spring Hanger at node 36. Carpenter & Paterson hanger table
Element 37-40
o Change the from node from 37 to 36
o Edit the length of this element to 1715 mm
Node 43
o Remove the Spring hanger

INTERGRAPH
307
Element 50-57
o Create a new node number 55, located 3250mm from node 50
o Remove the +Y support at node 57
o Add a Carpenter Spring Hanger at node 55
Element 70-77 * Formatted: No Spacing, No bullets or

o Change the to node to be 72 numbering
o Edit the length to be 2000mm

o Edit the support node number to be 72
Element 77-80
o Change the from node to be 72
o Edit the length to be 2115mm
Element 80-90
o Create a new node number 85, located 1000mm from node 80
o Insert a +Y at this location
Determine the Load

Consider water hammer acting when the valve at node 70 slams shut. This creates an unbalanced
.
force due to the propagation of a pressure wave The water hammer load can be estimated using
Joukowski s equation:
F = DLF x A P x A
Where:
F = force acting on valve seat
DLF = dynamic load factor (use 2.0)
AP = pressure change
= pxcxAV
A = internal area of pipe (0.073 m2 for 12 std pipe)
3
p = density of fluid (1000kg/m for water )
c = speed of sound in the fluid (typ. 1000 - 2000 m/sec in water based on D/t)
AV = change of fluid velocity (typically 1.5 - 3 m/sec for water)
D = mean pipe diameter
t = pipe wall thickness
-
Wave speed 8i pressure change for water in steel pipe ( AP/AV= p c) :
D/t C (m/ sec ) AP/ AV (bar/(m/ sec ) )
20 1310 13.1
40 1210 12.1
60 1130 11.3
80 1065 10.65
Using D / 1= 314 / 9.5 = 33, AP/ AV = approximately 12.45 bar / (m/sec); assume AV = 2 m/sec;
so:
F = 2.0 x 12.45 x 2 x 0.073 = 364K N
(
INTERGRAPH
'
08
Define the Occasion Load

Model a Z-direction force at node 70, equal to 364,000 N, as calculated previously.
Bend Reducer T1
(3 Rigid SIFs 8, Tees

I Nodel 70
Expansion Joint
I3 Vector 1 Vector 2 Vector 3 Vector
Restraints Displacements 5 FX
8
Hangers Flange Checks SF-
Nozzle Flex. Nozzle Lmt Check FZ 364000 0
m-
0Forces/Moments MY
nUnrtarmkoads MZ
Wind / Wave in

Load Case Setup

Build the shock load case ( s ). The hammer load may be reversing, so build both a +F1 case and a -FI
case. Then build a SCALAR combination case combining the SUS and OCC load cases:

W - Weight L1 W HGR
T1 - Thermal Case #1 L2 W+T1+P1 HGR
P1 - Pressure Case #1 L3 W+T1+P1+H OPE
H - HangerLoads L4 W+P1+H SUS
L5 F1 OCC
F1 - Cone Force Case #1
WW - Water Riled Weight
L6 -F1 OCC
L7 L3 -L4 EXP
L8 L4+L5 OCC
L9 L4+L6 OCC
Lood Case Editor Load Cose Options WmdLoods Wave Loads
Output Output Comb Snubbers Hanger

Load Case Name Method Active? Stiffness
Status Type
L1 WEIGHT FOR HANGER LOADS Suppress DispfForce/Stiess Rigid EC

12 OPERATING FOR HANGER TRAVEL Suppress Disp/Force/SUess 3 Ignore EC
L3 OPERATING CASE CONDmOfl 1 Keep Disp/Force/Slress As Designe EC
L4 SUSTAINED CASE CONDITION 1 Keep Disp/Force/SUess As Designe EC
L5 Positive Hammer Load Keep Disp/Force/Stress As Designe EC
L6 NegatrveHammer Load Keep Disp/Force/Stress \ As Oesigne EC
L7 Expansion Case Keep Disp/Force /Stress Algebraic
L8 Sustained + Hammer Load Keep Disp/Force /Stress Scalar 0
L9 Sustained - Hammer Load Keep Disp/Force/Stress Scalar
s

INTERGRAPH
SUPT01 - Water Hammer
309
Check the Results

Immediately it can be seen that there are issues with the Occasional load cases. What is causing
these issues?
Is this an accurate simulation ? Viewing the restraint summary shows that the loads on the restraints
-
at nodes 22 and particularly 85 - both show zero load an immediate uplift - for at least one of the
hammer cases. If a +Y restraint actually lifted off, it would first have to overcome the pre-existing
downward load present during the operating case. So what we have here is not an accurate
simulation
Various Load Cases
FX FY MX MY MZ
NODE Load Case
N. N. N .
22 Rigid +Y
5(OCC) 0 0 0 0 c
6(OCC)
MAX
0
--
26527
26527/L6
0 0 0
85 Rigid +Y
5(OCC) 0 0 0
6(OCC) 0 0 0
Reset the Load Cases

This points out the danger when modelling occasional loads on non-linear systems: load stepping
must be considered , i.e., first apply the operating toads, then apply the occasional loads, then isolate
the occasional loads by subtracting the formerfromthe latter. This accurately models the effects of
the pre-existing restraint status. This can be done using the following load cases:

W - Weight L1 W HGR
-
T1 Thermal Case #1 L2 W+T1+P1 HGR
-
P1 Pressure Cose #1 L3 W+T1+P1+ H OPE
sus
-
H HangerLoads L4
L5
W+ P1+ H
W+T1+ P1+ H + F1 OPE
( F1 - Cone Force Case #1
L6 W+T1+ P1+ H-F1 OPE
-
WW Water Filled Weight
L7 -
L5 L 3 OCC
L8 L6-L3 OCC
L9 -
L 3 L4 EXP
L10 L4 + L7 OCC
L11 L4+ L8 OCC
Remember to change the load case combination method to Scalar for the OCC load cases in the load
case options tab.

(
INTERGRAPH
"
CADWora & Analysis Solutions
SUPTOl - Water Hammer
310
Load Cass Editor Load Case Options Wind Loads Wave Loads
Output Output Comb Snubbers

Load Case Name Type Method Active?
Status
L1 WEIGHT FOR HANGER LOADS Suppress Disp/Force/Stress

L2 OPERATING FOR HANGER TRAVEL Suppress Disp/Force / Stress
L3 OPERATING CASE CONDITION 1 Keep Disp/Force/Stress
L4 SUSTAINED CASE CONDITION 1 Keep Disp/Force/Stress
L5 Operating + Hammer Load Keep Disp/Force/Stress
L6 Operating - Hammer Load Keep Disp/Force/Stress ?- -
i
L7 Positive Hammer Load Keep Disp/Force /Stress Algebraic
L8 Negative Hammer Load Keep Disp/Force /Stress Algebraic
L9 Expansion Case Keep Disp/Force /Stress Algebraic
L10 Sustained + Hammer Load Keep Disp/Force /Stress Scalar
L11 Sustained - Hammer Load Keep Disp/Force /Stress Scalar
V /
There are still issues in the OCC load cases, but
Note that even though the pipe lifts off of the restraint at node 22, the occasional only load, Load
Case 7, does overcome the pre-existing operating load first, for an accurate simulation of events:

Various Load Cases
NODE Load Case FX FY FZ MX MY MZ

N. N. N. N.m. N.m. N.ra.
22 Rigid +Y
3(OPE) 0 -21921 0 0 0 0
4(SUS)
5(OPE)
0
0
-12754 0
0
0
0
0
0
0
0
6(OPE)
7(OCC)
0
0
-45879
21921
0
0
0
0
0
0
0
0
B(OCC)
MAX
0
-- 2395 B
45879/L6
0 0 0 0
The Code Compliance Evaluation shows that the system is still highly overstressed under this OCC
load. This problem can be resolved by adding restraint (since the water hammer is a primary load ).
We can use a rigid Z-restraint to contain the water hammer if we can find a point in the vicinity of
the load ( run 50-80) where the Z-operating displacement is negligible (so the previous expansion and
sustained analyses will be relatively unaffected). A good candidate is at node 78 as the OPErating
displacement report shows.
Copyright 2011 Intergraph CADWorx 8i Analysis Solutions

INTERGRAPH


DX DY DZ RX RY RZ
nun. mm. mm. deg. deg . deg.
55 -7.918
8.522 -4.890 14.233 0.0239 -0.0115
0.0090 -0.0437
57
60
-
-7.888
-2.721
-2.569
7.915
7.636
0.0571
0.0590
-0.0117
-0.0117
-0.0375
-0.0372
0.0372
70 -7.340
7.784 -2.045 6.693 0.0592 - -0.0335
77
78
-6.909
-
- 0.000
0.838 | |
| -0.095
9 Qfl 1 0.0446
0.0202
--0.0139
0.0160
-
-0.0322
0.0305
79
80
-6.558
-4.901
5.909
0.838
0.689
--0.651
0.781
0.0094
0.0096
-0.0200
-0.0210
-0.0248
-
85 - 0.466 -0.582 0.0079 --0.0202 -0.0215
90 0.000 -0.000 - 0.000 0.0000 0.0000 - 0.0000
Correct model
Return to the input and select element 72-80. Node 78 is on the 0 angle of the bend at the to end
of this element.
Radius: HIM
Type:
Angle 1 M Node 1 79
Angle 2 0000 Node 2 78

Angle 3 Node 3
Place a Z restraint at this location

From |7Z L 0 Bend Reducer
. , LJ Nome Rigid SIFs & Tees \
To: 80[ Node 70 CNode
DX r~

Expansion Joint
i ( *0 Restraints !
!| Displacements
Type Z
- Gap
DY
0Mangers
- 1
Flange Checks
V
SUf Q Mu
Nozzle Rex Nozzle Lmt Check

DZ: [-211S 000 mm Node | CNode
Forces /Moments
QOdsals Type w Gap
nUniform Loads

/
(
INTERGRAPH

SUPTOl - Water Hammer
With a Z-restraint at node 78, the stresses have decreased significantly

CODE COMPLIANCE EXTENDED REPORT: Code Stresses on Elements
Various Load Cases
Code Allowable Code Allowable Ratio

Load Case Stress Stress Ratio TO Node Stress stress Piping Code
%
N./sq.mm. N./sq.mm. * N./sq.mm. N./sq.mm.
*** CODE COMPLIANCE EVALUATION PASSED ***
.
Highest Stresses: (N /sq.mm. )
CodeStress Ratio (%) is 30.4 at Node 72 LOADCASE: 10 (OCC) L10=L4+L7
Axial Stress: 46.9 @Node =
72 LOADCASE: 10 (OCC) L10 L4+L7
Bending Stress: 56.9 Node 40 LOADCASE: 9 (EXP) L9=L3 L4-
Torsion Stress: 1.6 @Node = -
22 LOADCASE: 9 (EXP) L9 L3 L4
22 LOADCASE: 4 (SUS) W+Pl+H
Hoop Stress:
3D Max Intensity:
4(SUS) 20
16.8
57.5
10.73
@Node
@Node
137.89 7.8 2!2

-
40 LOADCASE: 9 (EXP) L9 L3 L4
17.10
-
137.89 12.4 B31.3
9(EXP) 7.02 334.00 2.1 8.92 327.63 2.7 B31.3
10(OCC) 10.78 183.40 5.9 17.13 183.40 9.3 B31.3
ll(OCC) 10.78 183.40 5.9 17.13 183.40 9.3 B31.3

Caesar II Static Training

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INTERGRAPH

CAESAR II Statics Training

CAESAR II Version 2011 - Statics Training

Prepared by: Chris Bradshaw

Copyright 2011 Intergraph CADWorx & Analysis Solutions

CADWorx & Analysis Solutions

Default Data Directory 6

Maximum Stress Intensity Criterion 38

Code Stress Equations 40

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Combine Models 114

API 610 Analysis 160

Fix Model - Part 2 167

Model the Expansion Joint Assembly 194

Cool Hz0 - FRP Piping 218

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Review Results 237

Gas Transmission Pipeline - Buried Pipe 253

Material Database 259

Restraint Parameters 262

Load Case Setup 274

Product Line 285

B31.4 Code Requirements 290

Wave Solution 292

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Load Case Setup . 302

Determine the Load 307

Check the Results 309

Correct model 311

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Default Data Directory

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Create Custom Units File

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Existing Rle to Review

Existing Rle to Start From:

New Units Rle Name

View / Edit Rle Cancel

Give the file a label as well to easily identify the file.

Length inches * 25 4 '

Units File Label

First we will create the model in CAESAR II.

Create a new file in CAESAR II, called FKLateral

New Job Name S

Enter the name for the NEW job file:

9> Piping Input Structural Input

Enter the data directory

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Review Current Units

Moment-output in.Hb. 00833333

Stress Ibs. / sq in. 1

Pressure psig 1 Ib sq in Cmpd Lng inches 0.0833333 ft

Elastic Modulus Ibs. / sq.in. 1

Pipe Density Ibs./cu.in. 1

Insulation Den. Ibs./cu.in. 1

Units File Label: ENGUSH

In the CAESAR II main window select Tools > Configure /Setup

D e I ISLB . Configure/ Setup

Copyright 2011 Intergraph CADWorx & Analysis Solutions

Save and exit.

C1I CAESAR II - [D:\TRAIf

Copyright 2011 Intergraph CADWorx & Analysis Solutions

The model will be as follows:

Copyright 2011 Intergraph CADWorx & Analysis Solutions