CAESAR II
Training
Article 4
This prepared
by Engineer Antar Mustafa
[Link]@[Link]
+201064724668
➢ Contents of article 3
1. Example
2. Piping loads and stresses
3. 3D State of Stress in the Pipe Wall
4. Failure Theories
5. Maximum Stress Intensity Criterion
6. Code Stress Equations……………….……………Article 4
➢ Contents of article 4…………………………..………page
1. Code Stress Equations……………..…….……………3
2. B31.1 Power Piping ………………….………..……… 4
3. Pipe 1 ……………………… …………………………..……6
4. Input Model ……………………… ……………..……… 8
5. Error Checking ………………….…..…………..………17
6. Review Load Cases………………………………………20
7. Review Results ………………………..……………Article 5
➢ Code Stress Equations
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 S1–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 to be using in
place of in the sustained stress calculations.
➢ Note also that there are many additional piping codes addressed by CAESAR II.
➢ B31.1 Power Piping
The B31.1 code requires that the engineer calculate sustained, expansion and occasional
stresses, exactly defined as below:
▪ Sustained
Where: sustained stress
ί = intensification factor
MA =resultant moment due to sustained (primary) loads
= 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. ¼ of the ultimate tensile strength of the material at operating temperature
2. ¼ 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
➢ Expansion
Where: = expansion stress range
= resultant range of moments due to expansion (secondary) loads
=
= Allowable expansion stress
= basic allowable material stress at the cold (installation)
temperature, as per Appendix A of B31.1 Code
➢ Occasional:
Where: = Occasional Stresses
= resultant moment due to occasional loads
=
= 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.
➢ 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.
• 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:
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.
➢ Input Model
Enter A106-B as the material, 330°C as the temperature and 17 bars
as the pressure, In this model we also require insulation;
65mm thick Calcium Silicate.
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).
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.
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 -400mm
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.
The Auxiliary Data – Restraints window will
appear. Specify that the anchor is at node 10.
The auxiliary data window can now be closed.
Our first element is complete, and should look like the one
below:
Use the Continue This next element is a 300# flanged gate valve. We could enter this in a
button to create number of ways. The valve will be rigid relative to the surrounding
a new element: 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 II’s catalogue, which
The Flange – Valve – we will do.
Flange check box can Select the Valve flange data
be used to split the base button and select a gate
component into 3 valve with flanged ends,
elements ifrequired. class 300.
The element will appear The correct length will be inserted (and the element will
in node 20 to 30. 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).
Continue to the next element
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.
The bend auxiliary data window will appear.
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.
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.
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”x12”
Continue to the next element concentric reducer and is
203mm in length. Enter DX
The Reducer Auxiliary will appear and we as -203mm and specify that
can specify further data, including the second end size. this is a reducer.
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
Continue to the next element
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:
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.
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. Duplicate the selected elements and
choose to mirror about the Y-Z plane. 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.
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.
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.
The Edit Node numbers window
There are various ways of should now read 13 to 140 and
doing this – either double the element will be highlighted
click in the graphics area, in the model.
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).
Simply change the “To” node from 140 to 70.
The model will now be connected as should look like the one below:
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
The node numbers will default to 70 to 80.
We need to change this to 70 to 140.
This element is the vertical leg, and is 7m in
the Y direction. DY is therefore 7000.
This also leads 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
Select the Displacements button and enter in the required
Notice in the isometric that at values 3mm in DZ and 12mm in DY.
the vessel connection, there
are DY and DZ displacements.
These are due to the thermal
expansion of the vessel.
➢ Error Checking
The model is now complete, so run the error checker.
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.
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. A displacement of zero will
Click OK in the message which appears. fix the node in that direction,
Now edit the displacements and fill in 0 in all so now our node is fixed in
other field (DX,RX,RY,RZ). all directions, except for DY
where the relevant displacements are applied.
Re run the error checker and investigate the warnings.
The second two warnings are regarding the reducer
alpha angle which is not specified.
CAESAR II 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:
The Zoom to Node if found check box
will also zoom into that node/element
if it is found, useful on larger models.
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.
Select an unreinforced tee. 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
Re-run the error checker. B31.3 requires that two checks are performed – Sustained
All should now be OK, only and Expansion Sustained – Weight and Pressure
the reducer alpha warnings Expansion – Temperature and Displacement
will remain, plus the C of G report. These load cases are defined by CAESAR II as the default
➢ Review Load Cases (recommended) load cases, shown in rows L2 and L3.
Access the load case editor
Row L1 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 L1 and L2 (L1 – L2).
Accept these load cases and run the analysis by clicking the “Running Man” icon.
➢ Review Results
After the analysis has run, the out
put 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.
The report shows that the code stress check failed and highlights in
red where the check failed.
