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computercaesar-ii
Pipe stress analysis by computer CAESAR II
1. Mathematical model of piping system built using Caesar II software.
2. Engineers nowadays do not have to worry about solving higher degree, or differential
equations to perform complicated calculations, because they can create complete models of the
system they are trying to design and analyse and let the software perform the analysis for them.
However as the saying goes, “garbage in; garbage out” the engineer still has to possess good
engineering judgment to know what to expect from a computer analysis and how to interpret the
output. Although there are various softwares available to do pipe stress analyses, Caesar II is
one that is well known and frequently used for the oil and gas engineering analyses.
3.  CAESAR II is most often used for the mechanical design of new piping systems.
Hot piping systems present a unique problem to the mechanical engineer—these irregular
structures experience great thermal strain that must be absorbed by the piping, supports, and
attached equipment. These “structures” must be stiff enough to support their own weight and
also flexible enough to accept thermal growth. These loads, displacements, and stresses can be
estimated through analysis of the piping model in CAESAR II. To aid in this design by analysis,
CAESAR II incorporates many of the limitations placed on these systems and their attached
equipment. These limits are typically specified by engineering bodies (such as the ASME B31
committees, ASME Section VIII, and the Welding Research Council) or by manufacturers of
piping-related equipment (API, NEMA, or Expansion Joint Manufacturers’ Association -
EJMA). CAESAR II is not limited to thermal analysis of piping systems. CAESAR II also has
the capability of modeling and analyzing the full range of static and dynamic loads, which may
be imposed on the system. Therefore, CAESAR II is not only a tool for new design but it is also
valuable in troubleshooting or re-designing existing systems. Here, one can determine the
cause of failure or evaluate the severity of un-anticipated operating conditions such as
fluid/piping interaction or mechanical vibration caused by rotating equipment.
4.  Each time CAESAR II starts, the configuration file caesar.cfg is read from the
current data directory. If this file is not found in the current data directory, eventually a fatal error
will be generated and CAESAR II will terminate. To generate the caesar.cfg file select
Tools/Configure/Setup (or the Configure button from the toolbar) from the CAESAR II Main
Menu. Once finished users must click Exit w/Save at the bottom of the Configure/Setup
window to create a new configuration file or to save changes to the existing configuration file.
The configuration program produces the Computation Control window. Important: The
caesar.cfg file may vary from machine to machine and many of the setup directives modify the
analysis. The units' file, if modified by the user, would also need to be identical if the same
results are to be produced. See the next slide for an image of the Computational Control panel.
5.  Use Pressure Stiffening on Bends- if used it will be the maximum of all psi Missing
Mass ZPA- defaults to the last “extracted” mode Bend Axial Shape- if ignored the bend will be
stiffer Rod Tolerance (degrees)- The default of CAESAR II is 1.0 degree Rod Increment
(Degrees)- for difficult-to-converge problems, use 0.1 Alpha Tolerance- the default value is
0.05 Ambient Temperature- use the ambient temperature Friction Stiffness- default value is
1.0E6 lb./in (non-sliding) Friction Normal Force Variation- default value is 0.15, (15%)
Friction Angle Variation- the default is 15 degrees Friction Slide Multiplier- should never be
adjusted by the user Coefficient of Friction (Mu)- user defined (0 = no friction) WRC-107
Version / WRC-107 Interpolation Method- the default is to use the last value in the particular
WRC table In-core Numerical Check- user enabled Decomposition Singularity Tolerance-
the default value is 1.0 E10. Minimum Wall Mill Tolerance (%)- default value is 12.5, (12.5%)
Bourdon Pressure- user choice except for FRP pipe; always considered Include / Ignore
Spring Hanger Stiffness- user enabled Hanger Default Restraint Stiffness- default value is (1.0
E12 lb/in) Default Translational Restraint Stiffness- default value is (1.0 E12 lb/in) Default
Rotational Restraint Stiffness- default value is (1.0 E12 in-lb/deg)
6.  Default Code The piping code the user designs to most often should go here. This
code will be used as the default if no code is specified in the problem input. The default piping
code is B31.3, the chemical plant and petroleum refinery code. Valid entries are B31.1, B31.3,
B31.4, B31.4 Chapter IX, B31.5, B31.8, B31.8 Chapter VIII, B31.11, ASME-NC(Class 2),
ASME-ND(Class 3), NAVY505, Z662, Z662 Chapter 11, BS806, SWEDISH1, SWEDISH2,
B31.1-1967, STOOMWEZEN, RCCM-C, RCCM-D, CODETI, Norwegian, FDBR, BS-7159,
UKOOA, IGE/TD/12, DNV, EN-13480, and GPTC/192. Occasional Load Factor B31.3 states,
“The sum of the longitudinal stresses due to pressure, weight, and other sustained loadings (S1)
and of the stresses produced by occasional loads such as wind or earthquake may be as much
as 1.33 times the allowable stress given in Appendix A…” The default for B31.3 applications is
33%. If this is too high for the material and temperature specified then a smaller occasional load
factor could be input. Yield Stress Criterion: Von Mises Theory or the Maximum Shear
Theory
7.  B31.3 Sustained SIF Multiplier - the default is 1.0 B31.3 Welding and Contour
Tees Meet B16.9- the default setting for this directive is “NO”, which causes the program to use
a flexibility characteristic of 3.1*T/r, as per the A01 addendum. Allow User's SIF at Bend- the
default is off Use WRC 329- this activates the WRC329 guidelines for all intersections Use
Schneider- activates the Schneider reduced intersection assumptions All Cases Corroded- if
enabled, uses the corroded section modulus Liberal Expansion Stress Allowable- user choice
to make it default Press. Variation in Expansion Case- user controlled Base Hoop Stress On
( ID/OD/Mean/Lamés )- The default is to use the ID of the pipe. If enabled, hoop stress value
has the following options: ID—Hoop stress is computed according to Pd/2t where “d” is the
internal diameter of the pipe. OD—Hoop stress is computed according to Pd/2t where “d” is
the outer diameter of the pipe. Mean—Hoop stress is computed according to Pd/2t where “d”
is the average or mean diameter of the pipe. Lamés—Hoop stress is computed according to
Lamés equation, = P ( Ri2 + Ri2 * Ro2 / R2 ) / ( Ro2- Ri2 ) and varies through the wall as a
function of R
8.  Use PD/4t- The more comprehensive calculation, i.e. the Default, is
recommended Add F/A in Stresses- setting this to ‘Default’ causes CAESAR II to use
whatever the currently active piping code recommends. Add Torsion in SL Stress- setting to
‘Yes’ will include the torsion term in those codes that don’t include it already by default
Reduced Intersection- options are B31.1(Pre 1980), B31.1(Post 1980), WRC329, ASME SEC
III, and Schneider Class 1 Branch Flexibility- Activates the Class 1 flexibility calculations
B31.1 Reduced Z Fix- if used in conjunction with B31.1, it makes the correction to the reduced
branch stress calculation that existed in the 1980 through 1989 versions of B31.1 No
RFT/WLT in Reduced Fitting SIFs- If enabled will use distinct in-plane and out-of-plane SIFs
Implement B31.3 Appendix P- implements the alternate rules in B31.3 Appendix P.
9. Bends:Stiffened Bends90-degree BendsMitered BendsElbows Expansion
JointsSimple Bellows with Pressure ThrustTied BellowsUniversal JointsHinged
JointsSlip JointsGimbal JointsBall Joints Restraints:AnchorsGuidesLimit
StopsWindowsDouble-Acting Restraints Hangers:Single CanLiftoff Spring CanBottom-
out Spring CanConstant Effort HangersHanger w/ Sliding Movement Capability
Miscellaneous Reducers Jacketed Pipe
10.  Bends are defined by the element entering the bend and the element leaving the
bend. The actual bend curvature is always physically at the “TO” end of the element entering
the bend. (The element direction is defined from the first node to the second node.) The input
for the element leaving the bend must follow the element entering the bend. The bend angle is
defined by these two elements. Bend radius defaults to 1 1/2 times the pipe nominal diameter
(long radius), but may be changed to any other value. Specifying a bend automatically
generates two additional intermediate nodes, at the 0-degree location and at the bend midpoint
(M). For stress and displacement output the TO node of the element entering the bend is
located geometrically at the far-point on the bend. The far-point is at the weld line of the bend,
and adjacent to the straight element leaving the bend. Nodes defined in the Angle and Node
fields are placed at the given angle on the bend curvature. The angle starts with zero degrees at
the near-point on the bend and goes to degrees at the far-point of the bend.
11.  Nodes on the bend curvature cannot be placed closer together than specified by
the Minimum Angle to Adjacent Bend parameter in the Configure-Setup—Geometry section.
This includes the spacing between the nodes on the bend curvature and the near and far-points
of the bend. Entering the letter M as the angle designates the bend midpoints. The minimum
and maximum total bend angle is specified by the Minimum Bend Angle and Maximum Bend
Angle parameters in the Configure Setup—Geometry section.
12.  Single and double flanged bend specifications only affect the stress intensification
and flexibility of the bend. There is no automatic rigid element (or change in weight) generated
for the end of the bend. Single and double-flanged bends are indicated by entering 1 or 2
(respectively) for the Type in the bend auxiliary input. Rigid elements defined before or after
the bend will not alter the bend's stiffness or stress intensification factors. When specifying
single flanged bends it does not matter which end of the bend the flange is on. If the user
wishes to include the weight of the rigid flange(s) at the bend ends, then he/she should put rigid
elements (whose total length is the length of a flange pair) at the bend ends where the flange
pairs exist. As a guideline, British Standard 806 recommends stiffening the bends whenever a
component that significantly stiffens the pipe cross section is found within two diameters of
either bend end.
13.  Two 90-degree bends should be separated by twice the bend radius. The far-
point of the first bend is the same as the near-point of the second (following) the bend. The user
is recommended to put nodes at the mid point of each bend comprising the 180 degree return.
(See the example on this page)
14.  Evenly spaced mitered bends, whether closely or widely spaced, are uniquely
defined by two parameters: Number of cuts (changes in direction) Equivalent radius, or miter
spacing. For closely spaced miters the equivalent radius is equal to the code defined“R1” for
B31.3 and “R” for B31.1. The equation relating the equivalent radius to the spacing for evenly
spaced miters is: Req = S / [ 2 tan(Ɵ) ]Where: Req - equivalent miter bend radius S - spacing of
the miter cuts along the centerlineƟ - code defined half-angle between adjacent miter cuts: Ɵ =
α / 2N And where:α - total bend angle N - number of cuts
15.  An additional parameter ‘B’ (length of miter segment at crotch) is checked for
closely spaced miters when using B31.1. ‘B’ may be found for evenly spaced miters from
equation: B = S [ 1 - ro / Req ] Where: ro - outside radius of pipe cross-section Miter bends are
closely spaced if: S < r [ 1 + tan (Ɵ) ]Where: S - miter spacing r - average pipe cross section
radius: (ri+ro)/2Ɵ - one-half the angle between adjacent miter cuts. ASME B31.1 has the
additional requirements that: B > 6 tnƟ ≤ 22.5 deg. B - length of the miter segment at the crotch.
tn - nominal wall thickness of pipe.
16.  Closely spaced miters regardless of the number of miter cuts may be entered as a
single bend. CAESAR II will always calculate the spacing from the bend radius. If the user has
the miter spacing and not the bend radius, the radius must be calculated as shown below. The
mitered bend shown 2 slides above has 4 cuts through 90 degrees and a spacing of 15.913
inches. Req = S / [ 2 tan (Ɵ) ]Ɵ = α / 2N = 90 / [2(4)] = 11.25 deg. Req = 15.913 / [2 tan (11.25
deg.)] = 40
17.  Mitered bends are widely spaced if: S ≥ r * [1 + tan (Ɵ)]S - spacing between miter
points along the miter segment centerline. r - average cross section radius (ri+ro)/2Ɵ - one-half
angle between adjacent miter cuts. B31.1 has the additional requirement that: ≤Ɵ 22.5 deg.
In CAESAR II, widely spaced miters must be entered as individual, single cut miters, each
having a bend radius equal to: R = r [1 + cot (Ɵ)] / 2 R - reduced bend radius for widely spaced
miters. During error checking, CAESAR II will produce a warning message for each mitered
component, which does not pass the test for a closely spaced miter. These components should
be re-entered as a group of single cut joints.
18. Pipe O. D. = 10.375 in Pipe Thk. = 0.500 in Bend Angle = 90 degrees Cuts = 2 Req
= 45 in Calculate the Δ coordinates to get from the tangent intersecting point of the single cut
miter bend at node 10 to the single cut miter bend at node 15. Note: The straight pipe section
coming into and going out of the bend must be ≥ Req sin (Ɵ).
19.  When the fitting thickness in the bend auxiliary field is entered, CAESAR II
changes the thickness of the curved portion of the bend element only. The thickness of any
preceding or following straight pipe is unaffected. The specified fitting thickness applies for the
current elbow only and is not carried on to any subsequent elbows in the job. Stresses at the
elbow are calculated based on the section modulus of the matching pipe as specified in the B31
codes. However, stress intensification factors and flexibility factors for the bend are based on
the elbow wall thickness. The elbow at node 10 (in the next slide) has a thickness larger than
the matching pipe wall. The matching pipe has a thickness of 0.5
20.  Anchors; Connecting nodes can be used with anchors to rigidly fix one point in the
piping system to any other point in the piping system. Double-acting restraints; Double-acting
restraints are those that act in both directions along the line of action. Most commonly used
restraints are double-acting. A CNode is the connecting node. Single-directional restraints;
Friction and gaps may be specified with single-directional restraints. A CNode is the connecting
node. Guides; Guides are double-acting restraints with or without a specified gap. Connecting
Nodes (CNodes) can be used with guides. Limit Stop; Limit stops are single- or double-acting
restraint whose line of action is along the axis of the pipe. These can have gaps too. A gap is a
length, and is always positive. Windows; Equal leg windows are modeled using two double-
acting restraints with gaps orthogonal to the pipe axis. Unequal leg windows are modeled using
four single-acting restraints with gaps orthogonal to the pipe axis.
21.  Vertical / Horizontal Dummy Legs; Dummy legs and/or any other elements
attached to the bend curvature should be coded to the bend tangent intersection point. For each
dummy leg/bend model a warning message is generated during error checking in CAESAR II.
Large Rotation rods; Large rotation rods are used to model relatively short rods, where large
orthogonal movement of the pipe causes shortening of the restraint along the original line of
action. These can be entered in any direction. Large rotation is generally considered to become
significant when the angle of swing becomes greater than 5 degrees. Static Snubbers;
Translational restraints that provide resistance to displacement in static analysis of occasional
loads only. Static snubbers may be directional, (i.e. may be preceded by a plus or minus sign).
Plastic Hinges; Two bi-linear supports are used to model rigid resistance to bending until a
breakaway force (yield force) is exceeded at which point bending is essentially free. Sway
Brace assemblies; The sway brace is composed of a single compression spring enclosed
between two movable plates. Manufacturers typically recommend a specific size sway brace for
a given pipe nominal diameter.
22. The hanger design algorithm will not design hangers that are completely predefined.
Any other data can exist for the spring location but this data is not used. Entered spring rates
and theoretical cold loads will be multiplied by the number of hangers at this location. CAESAR
II requires the Theoretical Cold (Installation) Load to pre-define the spring. Theoretical Cold
Load = Hot Load + Travel * Spring Rate where upward travel is positive.
23. The basic parameters input into CAESAR II describe the wave height and period,
and the current velocity. The most difficult to obtain, and also the most important parameters,
are:the drag, Cdinertia, Cm andlift coefficients, Cl Based on the recommendations of API
RP2A and DNV (Det Norske Veritas), values for Cd range from 0.6 to 1.2, values for Cm range
from 1.5 to 2.0. Values for Cl show a wide range of scatter, but the approximate mean value is
0.7. The inertia coefficient Cm is equal to one plus the added mass coefficient Ca. This added
mass value accounts for the mass of the fluid assumed to be entrained with the piping element.
In actuality, these coefficients are a function of the fluid particle velocity, which varies over the
water column. In general practice, two dimensionless parameters are computed which are used
to obtain the Cd, Cm, and Cl values from published charts.
24. This is a critical item for leakage determination and for computing stresses in the
flange. The ASME code bases its stress calculations on a pre-specified, fixed equation for the
bolt stress. The resulting value is however often not related to the actual tightening stress that
appears in the flange when the bolts are tightened. For this reason, the initial bolt stress input
field that appears in the first section of data input, Bolt Initial Tightening Stress, is used only for
the flexibility/leakage determination. The value for the bolt tightening stress used in the ASME
flange stress calculations is as defined by the ASME code: Bolt Load = Hydrostatic End Force +
Force for Leak-tight Joint If the Bolt Initial Tightening Stress field is left blank, CAESAR II uses
the value: 45000 / √(dbolt) where 45,000 psi is a constant and d is the nominal diameter of the
bolt (correction is made for metric units).
25. This is a rule of thumb tightening stress, that will typically be applied by field
personnel tightening the bolts. This computed value is printed in the output from the flange
program. It is interesting to compare this value to the bolt stress printed in the ASME stress
report (also in the output). It is not unusual for the “rule-of-thumb”tightening stress to be larger
than the ASME required stress. When the ASME required stress is entered into the Bolt Initial
Tightening Stress data field, a comparison of the leakage safety factors can be made and the
sensitivity of the joint to the tightening torque can be ascertained. Users are strongly
encouraged to “play” with these numbers to get a feel for the relationship between all of the
factors involved.
26.  To define an expansion joint, activate the Expansion Joint check box (see
"Expansion Joints" on page 3-21 of the Caesar II manual) on the pipe element spreadsheet.
The expansion joint will have a non-zero length if at least one of the element’s spreadsheet
Delta fields is non-blank and non-zero. This will usually result in a more accurate stiffness model
in what is typically a very sensitive area of the piping system. Four stiffnesses define the
expansion joint: Axial Stiffness Transverse Stiffness Bending Stiffness Torsional Stiffness
These stiffnesses are defined as shown in the figure shown in the next slide:
27. Axial Stiffness Transverse Stiffness Bending StiffnessTorsional Stiffness
28. The equation for estimating bellows’ torsional stiffness is: Where,π = 3.14159 Re =
Expansion joint effective radius t = Bellows thickness E = Elastic Modulusν = Poisson’s Ratio L
= Flexible bellows length CAESAR II will calculate pressure thrust on the expansion joint if the
bellows effective I.D. is given in the expansion joint auxiliary screen. The mathematical model
for pressure thrust applies a force equal to the pressure times the effective area of the bellows
at either end of the expansion joint. The force will tend to open the bellows if the pressure is
positive, and close the bellows if the pressure is negative.
29. According to EJMA (Expansion Joint Manufacturers Association), the maximum
permitted amount of axial movement per corrugation is defined as erated where, ex + ey + eq <
erated The terms in the above equation are defined as: ex = The axial displacement per
corrugation resulting from imposed axial movements. ey = The axial displacement per
corrugation resulting from imposed lateral deflections. eq = The axial displacement per
corrugation resulting from imposed angular rotation, i.e. bending. erated = The maximum
permitted amount of axial movement per corrugation. This value should be obtained from the
Expansion Joint Manufacturer’s catalog.
30. The EJMA states:“Also, [as an expansion joint is rotated or deflected laterally] it
should be noted that one side of the bellows attains a larger projected area than the opposite
side. Under the action of the applied pressure, unbalanced forces are set up which tend to
distort the expansion joint further. In order to control the effects of these two factors a second
limit is established by the manufacturer upon the amount of angular rotation and/or lateral
deflection which may be imposed upon the expansion joint. This limit may be less than the rated
movement. Therefore, in the selection of an expansion joint, care must be exercised to avoid
exceeding either of these manufacturer’s limits.”
31. CAESAR II computes the terms defined in the erated equation and the movement of
the joint ends relative to each other. These relative movements are reported in both the local
joint coordinate system and the global coordinate system. The expansion joint rating module
can be entered by selecting Main Menu Analysis - Expansion Joint Rating option.
32. Spring Design Requirements The smallest single spring that satisfies all design
requirements is selected as the designed spring. The spring design requirements are:Both the
hot and the cold loads must be within the spring allowed working range.If the user specified an
allowed load variation then the absolute value of the product of the travel and the spring rate
divided by the hot load must be less than the specified variation.If the user specified some
minimum available clearance then the spring selected must fit in this space. If a single spring
cannot be found that satisfies the design requirements, CAESAR II will try to find two identical
springs that do satisfy the requirements. If satisfactory springs cannot be found, CAESAR II
recommends a constant effort support for the location.
33. Setting Up the Spring Load Cases The load cases that must exist for hanger design,
as described above, are: Restrained Weight Operating Installed Weight ...if the user
requested actual hanger installed loads. After the hanger algorithm has run the load cases it
needs to size the hangers. The newly selected springs are inserted into the piping system and
included in the analysis of all remaining load cases. The spring rate becomes part of the global
stiffness matrix, and is therefore added into all subsequent load cases.
34. When the Class 1 branch flexibilities are used, intersection models in the analysis
will become stiffer when the reduced geometry requirements do not apply, and will become
more flexible when the reduced geometry requirements do apply. Stiffer intersections typically
carry more load, and thus have higher stresses (lowering the stress in other parts of the system
that have been “unloaded”).More flexible intersections typically carry less load, and thus have
lower stresses, (causing higher stresses in other parts of the system that have “picked up” the
extra load).
35. When the reduced branch rules apply, the following equations are used for the local
stiffnesses: TRANSLATIONAL: AXIAL = RIGID CIRCUMFERENTIAL = RIGID LONGITUDINAL
= RIGID ROTATIONAL: AXIAL = RIGID CIRCUMFERENTIAL = (kx)d/EI LONGITUDINAL =
(kz)d/EI where: RIGID = 1.0 E12 lb./in. or 1.0 E12 in.lb./deg. d = Branch diameter E = Young’s
Modulus I = Cross Section Moment of Inertia D = Header diameter T = Header thickness Tb =
Branch fitting thickness kx = 0.1(D/T)1.5 [(T/t)(d/D)]0.5 (Tb/T) kz = 0.2(D/T)[(T/t)(d/D)]0.5 (Tb/T)
36. The Significance of the unbraced/unsupported span length“The significance of “k”
depends upon the specifics of the piping system. Qualitatively, if “k” is small compared to the
length of the piping system, including the effect of elbows and their k-factors, then the inclusion
of “k” for branch connections will have only minor effects on the calculated moments.
Conversely, if “k” is large compared to the piping system length, then the inclusion of “k” for
branch connections will have major effects. The largest effect will be to greatly reduce the
magnitude of the calculated moments acting on the branch connection. To illustrate the potential
significance of“k’s” for branch connections, we use the equation [above] to calculate “k” for a
branch connection with D=30 in., d=12.75 in. T=t=0.375 in.: k = 0.1(80)1.5 (0.425)0.5 * (1.0) =
46.6 This compares to the more typical rigid-joint interpretation that k=1, rather than k=46.6 !”
37. The following input parameters are required to get a leakage report. These
parameters include:Flange Inside DiameterFlange ThicknessBolt Circle DiameterNumber
Of BoltsBolt DiameterEffective Gasket DiameterUncompressed Gasket ThicknessEffective
Gasket WidthLeak Pressure RatioEffective Gasket ModulusExternally Applied
MomentExternally Applied ForcePressure
38. Leak Pressure Ratio This value is taken directly from Table 2-5.1 in the ASME
Section VIII code. This table is reproduced in the help screens of the software. This value is
more commonly recognized as “m”, and is termed the “Gasket Factor” in the ASME code. This
is a very important number for leakage determination, as it represents the ratio of the pressure
required to prevent leakage over the line pressure. Effective Gasket Modulus Typical values are
between 300,000 and 400,000 psi (20,684.27 and 27,579.03 bar) for spiral wound gaskets. The
higher the modulus the greater the tendency for the program to predict leakage. Errors on the
high side when estimating this value will lead to a more conservative design.
39. Flange Rating This is an optional input, but results in some very interesting output.
As mentioned above, it has been a widely used practice in the industry to use the ANSI B16.5
and API 605 temperature/pressure rating tables as a gauge for leakage. Because these rating
tables are based on allowable stresses, and were not intended for leakage prediction, the
leakage predictions that resulted were a function of the allowable stress for the flange material,
and not the flexibility, i.e. modulus of elasticity of the flange. To give the user a “feel” for this old
practice, the minimum and maximum rating table values from ANSI and API were stored and
are used to print minimum and maximum leakage safety factors that would be predicted from
this method. Example output that the user will get upon entering the flange rating is shown as
follows: EQUIVALENT PRESSURE MODEL ————————-Equivalent Pressure (lb./sq.in.)
1639.85 ANSI/API Min Equivalent Pressure Allowed 1080.00 ANSI/API Max Equivalent
Pressure Allowed 1815.00 This output shows that leakage, according to this older method,
occurred if a carbon steel flange was used, and leakage did not occur if an alloy flange was
used. (Of course both flanges would have essentially the same “flexibility” tendency to leak.)
40. The B31G criteria provides a methodology whereby corroded pipelines can be
evaluated to determine when specific pipe segments must be replaced. The original B31G
document incorporates a healthy dose of conservatism and as a result, additional work has
been performed to modify the original criteria. This additional work can be found in project report
PR-3805, by Battelle, Inc. The details of the original B31G criteria as well as the modified
methods are discussed in detail in this report. CAESAR II determines the following values
according to the original B31G criteria and four modified methods. These values are:The hoop
stress to cause failureThe maximum allowed operating pressureThe maximum allowed flaw
length
41. The four modified methods vary in the manner in which the corroded area is
estimated. These methods are:.85dL—The corroded area is approximated as 0.85 times the
maximum pit depth times the flaw length.Exact—The corroded area is determined numerically
using the trapezoid method.Equivalent—The corroded area is determined by multiplying the
average pit depth by the flaw length. Additionally, an equivalent flaw length (flaw length *
average pit depth / maximum pit depth) is used in the computation of the Folias
factor.Effective—This method also uses a numerical trapezoid summation, however, various
sub lengths of the total flaw length are used to arrive at a worst case condition. Note that if the
sub length which produces the worst case coincides with the total length, the Exact and
Effective methods yield the same result.
42. • Statics—Performs Static analysis of pipe and/or structure. This is available after
error checking the input file.• Dynamics—Performs Dynamic analysis of pipe and/or structure.
This is also available after error checking the input file.• SIFs—Displays scratch pads used to
calculate stress intensification factors at intersections and bends.• WRC 107/297—Calculates
stresses in vessels due to attached piping.• Flanges—Performs flange stress and leakage
calculations.• B31.G—Estimates pipeline remaining life.• Expansion Joint Rating—Evaluates
expansion joints using EJMA equations.• AISC—Performs AISC code check on structural steel
elements.• NEMA SM23—Evaluates piping loads on steam turbine nozzles.• API 610—
Evaluates piping loads on centrifugal pumps.• API 617—Evaluates piping loads on
compressors.• API 661—Evaluates piping loads on air-cooled heat exchangers.• HEI
Standard—Evaluates piping loads on feedwater heaters.• API 560—Evaluates piping loads on
fired heaters.
43. Static analysis cannot be performed until the error checking portion of the piping pre-
processor has been successfully completed. Only after error checking is completed are the
required analysis data files created. Similarly, any subsequent changes made to the model input
are not reflected in the analysis unless error checking is rerun after those changes have been
made. CAESAR II does not allow an analysis to take place if the input has been changed and
not successfully error checked.Error Checking can only be done from the input spreadsheet,
and is initiated by executing the Error Check or Batch Run commands from the toolbar or menu.
Error Check saves the input and starts the error checking procedure.Batch Run causes the
program to check the input data, analyze the system, and present the results without any user
interaction. The assumptionsare that the loading cases to be analyzed do not need to change
Users may sort messages in the Message Grid by type, message number or element/node
number by double-clicking the corresponding column header. Users can also print messages
displayed in the Message Grid.
44. A fatal error would be if no length were defined for a piping element, for example.
45. The software will give the user feedback when things are not right in the model.
Three types of messages are possible with Caesar II:Fatal Error Message - Errors are flagged
when there is a problem with the model due to which analysis cannot continue.Warning
Message - Warnings are flagged whenever there is a problem with a model, which can be
overcome using some assumptions.Note Message - The third category of alert is the
informational note. These messages simply inform the user of some noteworthy fact related to
the model. An example of a note may be a message informing the user of the number of
hangers to be designed by the software.
46. The first step in the analysis of an error-checked piping model is the specification of
the static load cases. After entering the static load case editor, a screen appears which lists all
of the available loads that are defined in the input, the available stress types, and the current
load cases offered for analysis. If the job is entering static analysis for the first time, CAESAR II
presents a list of recommended load cases. If the job has been run previously, the loads shown
are those saved during the last session. The load case input screen is shown on the next slide.
47. The user can define up to ninety-nine load cases. Load cases may be edited by
clicking on a line in the Load List area.
48. The following commands are available to define load cases: .Edit-Insert - Inserts a
blank load case following the currently selected line in the load list. If no line is selected, the
load case is added at the end of the list. Load cases are selected by clicking on the number to
the left of the load case.Edit-Delete - Deletes the currently selected load case.File Analysis -
Accepts the load cases and runs the job.Recommend - Allows the user to replace the current
load cases with the CAESAR II recommended load cases.Load Cycles - Hides or displays the
Load Cycles field in the Load Case list. Entries in these fields are only valid for load cases
defined with the fatigue stress type.
49. The following environmental parameters can be added to the model: .Wind Data:
Up to four different wind load cases may be specified for any one job. The only wind load
information that is specified in the piping input is the shape factor. It is this shape factor input
that causes load cases WIN1, WIN2, WIN3, and WIN4 to be listed as an available load to be
analyzed. More wind data is required, however, before an analysis can be made. There are
three different methods that can be used to generate wind loads on piping systems:ASCE #7
Standard Edition, 1995User entry of a pressure vs. elevation tableUser entry of a velocity vs.
elevation table The appropriate method is selected by placing a value of 1.0 in one of the first
three boxes.
50.  Hydrodynamic Parameters: Up to four different hydrodynamic load cases may be
specified for any one job. Several hydrodynamic coefficients are defined on the element
spreadsheet. The inclusion of hydrodynamic coefficients causes the loads WAV1, WAV2,
WAV3, and WAV4 to be available in the load case editor. In the load case editor, four different
wave load profiles can be specified. Current data and wave data may be specified and included
together or either of them may be omitted so as to exclude the data from the analysis. CAESAR
II supports three current models and six wave models.
51. List Input Format
52. The static analysis performed by CAESAR II follows the regular finite element
solution routine. Element stiffnesses are combined to form a global system stiffness matrix.
Each basic load case defines a set of loads for the ends of all the elements. These elemental
load sets are combined into system load vectors. Using the relationship of force equals stiffness
times displacement (F=K∙X), the unknown system deflections and rotations can be calculated.
The known deflections however, may change during the analysis as hanger sizing, nonlinear
supports, and friction all affect both the stiffness matrix and load vectors. The root solution from
this equation, the system-wide deflections and rotations, is used with the elements’ stiffness to
determine the global (X,Y,Z) forces and moments at the end of each element. These forces and
moments are translated into a local coordinate system for the element from which the code-
defined stresses are calculated. Forces and moments on anchors, restraints, and fixed
displacement points are summed to balance all global forces and moments entering the node.
Algebraic combinations of the basic load cases pick up this process where appropriate - at the
displacement, force & moment, or stress level. Once the setup for the solution is complete the
calculation of the displacements and rotations is repeated for each of the basic load cases.
53. Allowable Stress Increase Factor The Allowable Stress Increase Factor is a
multiplication factor applied to the computed values of the axial and bending allowable stresses.
Typically this value is 1.0. However, in extreme events the AISC code permits the allowable
stresses to be increased by a factor. Normally a 1/3 increase is applied to the computed
allowables, making the Allowable Stress Increase Factor = 1.33. Examples of extreme events
are earthquakes and 100 year storms. For more details see the AISC code, section 1.5.6.
Young’s Modulus The slope of the linear portion of the stress-strain diagram. For structural steel
this value is usually 29,000,000 psi (199,948 MPa). Material Yield Strength The specified
minimum yield stress of the steel being used.
54. Stress Reduction Factors Cmy and Cmz Cmy and Cmz are interaction formula
coefficients for the strong and weak axis of the elements (in-plane and out-of-plane).0.85 for
compression members in frames subject to joint translation (sidesway).For restrained
compression members in frames braced against sidesway and not subject to transverse loading
between supports in the plane of bending: 0.6 -0.4(M1/M2); but not less than 0.4where
(M1/M2) is the ratio of the smaller to larger moments at the ends, of that portion of the member
un-braced in the plane of bending under consideration.For compression members in frames
braced against joint translation in the plane of loading and subject to transverse loading
between supports, the value of Cmy may be determined by rational analysis. However, in lieu of
such analysis, the following values are suggested per the AISC code: a.0.85 for members
whose ends are restrained against rotation in the plane of bending b.1.0 for members whose
ends are unrestrained against rotation in the plane of bending
55. Bending Coefficient The bending coefficient Cb shall be taken as 1.0 in computing
the value of Fby and Fbz for use in Formula 1.6-1a. Cb shall also be unity when the bending
moment at any point in an un-braced length is larger than the moment at either end of the same
length. Otherwise, Cb shall be Cb = 1.75 + 1.05(M1/M2) + 0.3(M1/M2)2 but not more than 2.3
where (M1/M2) is the ratio of the smaller to larger moments at the ends. Form Factor Qa The
form factor is an allowable axial stress reduction factor equal to the effective area divided by the
actual area. (Consult the latest edition of the AISC code for the current computation methods for
the effective area.) Allow Sidesway The ability of a frame or structure to experience sidesway
(joint translation) affects the computation of several of the coefficients used in the unity check
equations. Additionally, for frames braced against sidesway, moments at each end of the
member are required. Normally sidesway is allowed (i.e., the box is checked).
56. The stress categories:SUStained,EXPansion,OCCasional,OPErating,
andFATigue These are specified at the end of the load case definition.
57. User defined retained output data Report
Options:DisplacementsRestraintsRestraint summaryGlobal element forcesLocal element
forcesStressesStress summaryCode compliance reportCumulative usage report The next
slide shows the on-screen static output processor.
58. Four types of dynamic analysis are possible:Natural Frequency
calculationsHarmonic analysisResponse Spectrum analysisEarthquake[Valve] Relief
loadsWater Hammer/Slug FlowTime History analysis
59. Caesar II’s dynamic analysis capabilities include:Natural Frequency calculations -
Natural frequency information can indicate the tendency of a piping system to respond to
dynamic loads. A system’s modal natural frequencies typically should not be too close to
equipment operating frequencies and, as a general rule, higher natural frequencies usually
cause less trouble than low natural frequencies.Harmonic analysis - These are ‘forcing
frequencies’ that include fluid pulsation in reciprocating pump lines or vibration due to rotating
equipment. These loads are modeled as concentrated forces or displacements at one or more
points in the system. To provide the proper phase relationship between multiple loads a phase
angle can also be associated with these forces or displacements.Response Spectrum analysis
- The response spectrum method allows an impulse type transient event to be characterized by
a response vs. frequency spectra. Each mode of vibration of the piping system is related to one
response on the spectrum. These modal responses are summed together to produce the total
system response. AndTime History analysis - This is one of the most accurate methods, in
that it uses numeric integration of the dynamic equation of motion to simulate the system
response throughout the load duration. requires more resources (memory, calculation speed
and time) than other methods. spectrum method might be a viable substitute if it offers sufficient
accuracy.
60. The dynamic analysis techniques employed by many softwares like Caesar II require
strict linearity in the piping and structural systems. Dynamic responses associated with
nonlinear effects are not addressed.An example of a nonlinear effect is “slapping”, such as
when a pipe lifts off the rack at one moment and impacts the rack the next. For the dynamic
model the pipe must be either held down or allowed to move freely. The nonlinear restraints
used in the static analysis must be set to be active or inactive for the dynamic analysis.A
second “nonlinear” effect is friction. Friction effects must also be“linearized” for use in dynamic
analysis. For example, if the normal force on the restraint from the static analysis is 350 lb., the
friction coefficient (mu) is 0.3, and the user defined Stiffness Factor for Friction is 50.0, then
springs having a stiffness of 350 * 0.3 * 50.0 = 5250 lb/in are inserted into the dynamic model in
the two directions perpendicular to the friction restraint’s line of action.
61. Developing dynamic input for CAESAR II comprises four basic steps: 1)Specifying
the load(s) 2)Modifying the mass and stiffness model 3)Setting the parameters that control the
analysis 4)Starting and error checking the analysis To enter the dynamics input, the proper job
name must be current prior to selecting the Analysis-Dynamics file options of the Main Menu.
62. below are the “code stress” equations for the actual and allowable stresses used by
CAESAR II. For the listed codes, the left hand side of the equation defines the actual stress and
the right hand side defines the allowable stress. The CAESAR II load case label is also listed
after the equation. US Code Stresses Stress Cat.
63. International Code Stresses Stress Cat.
64. BS 7159 (cont’d.)
65. MATERIAL NAME ELASTIC MODULUS (lb/in2) POISSON’S RATIO DENSITY
(lb/in3) TEMPERATURE RANGE (F) Low Carbon Steel 29.5 E6 0.2920 0.28993 -325 1400
High Carbon Steel 29.3 E6 0.2890 0.28009 -325 1400 Carbon Moly Steel 29.2 E6 0.2890
0.28935 -325 1400 Low Chrome Moly Steel 29.7 E6 0.2890 0.28935 -325 1400 Med Chrome
Moly Steel 30.9 E6 0.2890 0.28935 -325 1400 Austenitic Stainless 28.3 E6 0.2920 0.28930 -
325 1400 Straight Chromium 29.2 E6 0.3050 0.28010 -325 1400 Type 310 Stainless 28.3 E6
0.3050 0.28990 -325 1400 Wrought Iron 29.5 E6 0.3000 0.28070 -325 1400 Grey Cast Iron 13.4
E6 0.2110 0.25580 70 1000 Monel 67% Ni/30% Cu 26.0 E6 0.3150 0.31870 -325 1400 K-Monel
26.0 E6 0.3150 0.30610 -325 1400 Copper Nickel 22.0 E6 0.3300 0.33850 -325 1400 Aluminum
10.2 E6 0.3300 0.10130 -325 600 Copper 99.8% Cu 16.0 E6 0.3550 0.32270 70 400
Commercial Brass 17.0 E6 0.3310 0.30610 -325 1200 Leaded Tin Bronze 1 14.0 E6 0.3300
0.31890 -325 1200
66. PIPING CODE PUBLICATION DATE REVISION DATE ANSI B31.1 2004 16-Aug-04
ANSI B31.3 2004 29-Apr-05 ANSI B31.4 2002 4-Oct-02 ANSI B31.4 Chapter IX 2002 4-Oct-02
ANSI B31.5 2001 30-May-05 ANSI B31.8 2003 6-Feb-04 ANSI B31.8 Chapter VIII 2003 6-Feb-
04 ANSI B31.11 2002 30-May-03 ASME SECT III CLASS 2 2004 1-Jul-05 ASME SECT III
CLASS 3 2004 1-Jul-05 U.S. NAVY 505 1984 N/A CANADIAN Z662 (9/95) N/A CANADIAN
Z662 Ch 11 (9/95) N/A BS 806, ISSUE 1 Sept. 1993 N/A SWEDISH METHOD 1 2ND EDITION
STOCKHOLM, 1979 N/A SWEDISH METHOD 2 2ND EDITION STOCKHOLM 1979 N/A ANSI
B31.1 1967 N/A STOOMWEZEN 1989 N/A RCC-M C 1988 N/A RCC-M D 1988 N/A CODETI
2001 Jun-04 NORWEGIAN 1999 N/A FDBR 1995 N/A BS7159 1989 N/A UKOOA 1994 N/A
IGE/TD/12 2003 N/A DnV 1996 N/A EN-13480 (3/2002) N/A GPTC/192 1998 N/A
67. 1. COADE, “Version 5.00 CAESAR II Applications Guide” Caesar II Pipe Analysis
software, www.coade.com (E-mail at techsupport@coade.com) 2. British Standard, BS 806,
Pipe Bends 3. Water Resources Council (WRC) Specification 329 4. Caesar II enhancements
and reference topics, http://www.intergraph.com/products/ppm