PIPING STRESS ANALYSIS BY CAESAR-II SOFTWARE CAESAR MODELING
ANALYSIS REPORT
FDC PIPING
WHAT MAKES PIPING CRITICAL? •
Temperature
•
Pressure
•
Occasional loads (Seismic & Wind)
•
Dynamics of the flowing fluid
FDC PIPING
WHAT CAUSES STRESS IN THE PIPE? •
Live and Dead load (Piping component, Insulation, Flowing medium etc.).
•
Line pressure
•
Restraining of pipe expansion or Temperature gradient
•
Discharge reaction (E.g. Relief valves)
•
Seismic / Wind load
FDC PIPING
•
Dynamics of flowing fluid.
Cont….
WHY STRESS ANALYSIS IS TO BE DONE?
To ensure that all stresses in the piping system are within allowable limits.
To limit the loads on the equipment nozzle.
To limit the thermal displacement and sagging
To limit the loads on the supporting structures & flanged joints.
FDC PIPING
To avoid excessive piping vibration
WORK FLOW DIAGRAM FOR STRESS GROUP Process Dept.
Instrumentation Dept.
P&ID LDT
Instrument data
Fabrication and Erection Isometric
Piping Team Supports Loadings for pipe support selection, pipe displacements at operating temp.
Civil Dept.
SAQ, alongwith Stress Isometrics and other data
Site/ Field Spring, SPS, Specials data sheets, Site problem resolutions, Audit Reports
Mechanical Dept.
Stress Analysis Team Soil Characteristics
Civil and Structural Support loadings
Equipment G.A.'s
Stress Analysis Report
Cleat Loads, Nozzle loads if more than allowables
INPUT FOR STRESS
ANALYSIS
Stress Isometrics
LDT / P&ID
Equipment G.A.Drawing
Instrument(e.g.PSV/control valve) data sheet
FDC PIPING
SOFTWARE USED
Piping Stress Analysis Software
CAESAR II 4.5
In-house software (Tracking system) SATS SSTS CAESAR CONVERT FDC PIPING
MODELLING
Piping Components
Piping
Equipments
Restraints
Cont…. FDC PIPING
NODE SKETCH
Cont…. FDC PIPING
STRESS ISO MARKUP
CAESAR INPUT SPREADSHEET Start Run Batch Run
Allowable Stress At Cold Condition Geometry
Caesar Modelling Material Selection
Allowable Stress At Hot Condition
RESTRAINT MODELLING
SPRING MODELLING
CONSTANT SPRING
INPUT SPREADSHEET
FORCE MODELLING
BEND MODELLING
SEISMIC FORCE INPUT
PROCEDURE FOR PUMP LINE ANALYSIS PROCEDURE FOR PUMP LINE ANALYSIS REQUIRED DOCUMENTS
?
Pump line ISO, Pump vendor drg, allowable nozzle Load, P& ID, and LDT. In the
absence of allowable load in vendor drg, twice of API-610 values are used. CAESAR axis system should match with vendor drg or API-610 for comparing nozzle allowable loads and moments.
PUMP MODELING IN CAESAR-II Most commonly used centrifugal pumps are: 1. End suction – Top discharge 2. Top suction – Top discharge 3. Side suction – Side discharge For above mentioned pumps detail modeling procedure in CAESAR-II is discussed as below 1. End suction – Top discharge Referring to Fig.1, node marking 1-2 shows nozzle flange with given flange rating as “rigid” element. Node 2-3 shows nozzle standby with pipe element (dia equal to pump impeller dia and thickness equal to pipe wall thickness) as rigid element with zero weight from flange welding joint to pump impeller center line. Restraints – 1) The pipe flange to be get anchored as C- Node with pump flange to get nozzle load due to piping reaction. This load value should be less than allowable values. 2) Rigid element at Impeller C/L to be get anchored i.e. anchor at node3.
PROCEDURE FOR PUMP LINE ANALYSIS
2. Top suction – Top discharge & 3. Side suction – Side discharge Referring to Fig.2 & 3, node marking 1-2 shows nozzle flange with given flange rating as “rigid” element. Node 2-3 shows nozzle standby with pipe element (Dia equal to pump impeller dia and thickness equal to pipe wall thickness) as rigid element with zero weight from flange welding joint to pump impeller center line. Node 3-4 shows rigid element with zero weight up to center line of the pump. Restraints – 1) The pipe flange to be get anchored as C- Node with pump flange to get nozzle load due to piping reaction. This load value should be less than allowable values. 2) Rigid element at pump C/L to be get anchored i.e. anchor at node4.
PROCEDURE FOR PUMP LINE ANALYSIS
ANALYSIS
FDC PIPING
STATIC ANALYSIS
DYNAMIC ANALYSIS
TYPES OF STRESSES
FDC PIPING
PRIMARY
SECONDARY
TYPES OF LOAD
FDC PIPING
Sustain Load
Occasional Load
Thermal Load
Hydro Test Load
LOAD CASE DEFINATION
L1
WW + HP
(HYD)
L2
W + T1 + P1 + H
(OPE)
L3
W + T2 + P1 + H
(OPE)
L4
W + P1 + H
(SUS)
L5
L2 – L4
(EXP)
L6
L3 – L4
(EXP)
FDC PIPING
LOAD CASE DEFINATION
FDC PIPING
L1
W + T1 + P1 + H
(OPE)
L2
W + P1 + H
(SUS)
L3
U1
(OCC)
L4
U2
(OCC)
L5
L2 + L3
(OCC)
L6
L2 + L4
(OCC)
CAESAR LOAD CASES DESIGN TEMP. LOAD CASE OPERATING TEMP. LOAD CASE
PROCEDURE FOR PUMP LINE ANALYSIS LOAD CASES FOR PUMP LINE STRESS ANALYSIS Load cases for the pump connected lines are discussed below. 1. Hot Cold Load case:
♦ Both pump operating. When two or more pumps are used in a system then from stress analysis point of view the different load cases are made. Like,
♦ One pump operating & one stand by. (This point to be get discussed with process, what will be the requirement, whether “at any moment only one pump will operate, for more than two pump case”)
♦ Hot Cold analysis to be done at design and operating temperature.
♦ For the pump, which is not operating, ambient temperature should be considered from Tee point ► When two pumps are present in the system hot cold cases can be made as below (Refer Fig. 4).
PROCEDURE FOR PUMP LINE ANALYSIS Case 1: When both pumps are in operating condition, provide design and operating temperature for node 10-2030-40-A & 20-50-60-B
Case 2: When pump “A” is operating and pump “B” is cold, provide design and operating temperature for node 10-20-30-40-A and ambient temperature for 20-50-60-B.
Case 3: When pump “B” is operating and pump “A” is cold, provide design and operating temperature for node 10-20-50-60-B and ambient temperature for 2030-40-A. ► When three pumps are present in the system hot cold cases can be made as below (Refer Fig. 5).
PROCEDURE FOR PUMP LINE ANALYSIS CASE6: W+P1+T5 (OPE) ………Pump “A” at operating temp and Pump “B” standby. CASE7: W+P1+T6 (OPE) ………Pump “B” at operating temp and Pump “A” standby. CASE8: W+P1 (SUS) CASE9: WNC (SUS) CASE10: L2-L8 (EXP) CASE11: L3-L8 (EXP) CASE12: L4-L8 (EXP) CASE13: L5-L8 (EXP) CASE14: L6-L8 (EXP) CASE15: L7-L8 (EXP)
♦
For load case no 2, 3, 4, 5, 6,7and 8 pump nozzle load is checked and it should be within acceptable limit as specified by vendor or API 610.
♦ For load case no 1, 8, 10, 11,12,13,14 and 15 stress value is checked and it should be less than allowable stress as specified by relevant code.
♦ For load case no 9 (WNC case) deflection is checked at pipe flange for cold alignment case as discussed in earlier topic of WNC load case. B. Load Cases for Static Analysis (Three Pumps A, B & C) CASE1: WW+HP (HYD) CASE2: W+P1+T1 (OPE) …Three pumps at design temperature. CASE3: W+P1+T2 (OPE) …Three pumps at operating temperature. CASE4: W+P1+T3 (OPE) ….Pump “B&C” at design temp and Pump “A” standby. CASE5: W+P1+T4 (OPE) …..Pump “A&C” at design temp and Pump “B” standby. CASE6: W+P1+T5 (OPE) …..Pump “A&B” at design temp and Pump “C” standby. CASE7: W+P1+T6 (OPE) …..Pump “B&C” at operating temp and Pump “A” standby. CASE8: W+P1+T7 (OPE) …..Pump “A&C” at operating temp and Pump “B” standby. CASE9: W+P1+T8 (OPE) …..Pump “A&B” at operating temp and Pump “C” standby. CASE10: W+P1 (SUS) CASE11: WNC (SUS) CASE12: L2-L10 (EXP) CASE13: L3-L10 (EXP) CASE14: L4-L10 (EXP)
PROCEDURE FOR PUMP LINE Case 1: When three pumps are in operating condition, provide design and operating temperature for whole system. Case 2: When pump “A” is cold and pump “B & C” are operating, provide design and operating temperature to node 10-20-30-70-B & 20-50-60-C and ambient temperature for 30-40-80-A. Case 3: When pump “B” is cold and pump “A & C” are operating, provide design and operating temperature to node 10-20-30-40-80-A & 20-50-60-C and ambient temperature for 30-70-B Case 4: When pump “C” is cold and pump “A & B” are operating, provide design and operating temperature to node 10-20-30-40-80-A & 30-70-B and ambient temperature for 20-50-60-C. 2. WNC (Weight No Content) Load case: The basic philosophy for “WNC” is by what magnitude the piping flange displaced at the mating point while cold alignment. For “WNC” case, make the pump flange anchor node free and replace the spring support to rigid support. Go in load case spread sheet, drag the “WNC” from side menu to load case row and select “Sustain case”. Run the case and get the displacement at the pump nozzles, this displacement should be less than 1mm (or consult mechanical department to get allowable deflection). 3. Load Cases in CAESAR-II for two pump connected system Load cases for stress analysis of two pump connected piping system are discussed below. Same philosophy is applicable for more than two pump connected system. Abbreviation: W = Weight; T= Temperature; HP = Hydro Pressure; WW = Water Filled Weight; WNC = Weight No Contents; P = Design Pressure. U1 = Uniform load (NS Seismic); U2 = Uniform load (EW Seismic); A. Load Cases for Static Analysis (Two Pumps A & B) CASE1: WW+HP (HYD) CASE2: W+P1+T1 (OPE) ………Both pumps at design temperature. CASE3: W+P1+T2 (OPE) ………Both pumps at operating temperature. CASE4: W+P1+T3 (OPE) ………Pump “A” at design temp and Pump “B” standby. CASE5: W+P1+T4 (OPE) ………Pump “B” at design temp and Pump “A” standby.
CAESAR OUT PUT
REPORT INTERPRETATION
FDC PIPING
Displacement
Restraints
Restraints Summary
Global Element Forces
Local Element Forces
Stresses
Sorted Stress
Code Compliance
REPORT INTERPRETATION
FDC PIPING
Hanger Table
Hanger Table W/Text
Input Echo
Miscellaneous Data
Load Case Report
Warnings
OUTPUT SHEET
REPORTING
FDC PIPING
Stress Analysis Query Front Sheet
Caesar Title Sheet
Stress Isometrics with markup
Load summary sheet
Spring / Bellow data sheet
SPS drawing
Caesar Load summary sheet
SAQ SHEET Stress Analysis Query Report
Job No. :
22960
Job Title :
Jamnagar Refinary Project -
Complex :
Coke
Description :
Tie-In for Heater
Package No. :
Coke-371-041-00
Analyst :
rajeshr
Isometrics :
A15-371PA017, A09-
Reason for analysis : Ref. Doc. :
Unit :
371
Title : QYI/COK
Rev.: 0
Caesar File name : KA041A00 Date of issue : 18/11/2003
Others
Enclosed - Stress Isometrics Caesar Dump -
Attached sheets Attached
Load Summary Report Caesar front sheet - for ref.
Attached Attached
Spring Report Spring Datasheets SPS drawing -
Stress Remarks:
Pump/Equipment datasheet/drawing -
Attached
Copy of LDT -
Attached
Line Checked for Tie -in to the existing line.
CAESAR DUMP
RESTRAINT OUTPUT
SPRING DATASHEET User is given an unlocked cell (F53) to write any special comment / note.
GO TO
MA INTENA NCE
EL 1 (U/S STL.)
CL
EL.2
CL C L EL1-EL2=1500 mm
''B'' TYPE HANGER SPRING DETAILS LINE NO.:
File name:
BA WB401D
951-WB401-10"-EC62EM-HC25 F1951-951-WB012A
ISO OR GA NO.:
BOTTOM CONNECTION Calc No.: TYPE:
16
32.626 KN
PIPE SIZE:
OPERATING LOAD:
32.812 KN
EL1.:
TEST LOAD:
48.939 KN
DESIGN TEMPERATURE:
TRAVEL (+ UP / - DOWN):
-0.560 mm
P/SUPP TYPE:
1.000 mm
MANUFACTURER:
SA RA THI
10"
49137 EL2.:
MATCODE
47637 EL3.: 150
NA
TRAVEL (LATERAL):
K
1.000
MA INTECE
RVB
SS
01-09-2003 Issued for Construction
RRR DES'N ENGR
SS CHKD BY
RELIANCE INDUSTRIES LIMITED JAMNAGAR REFINERY PROJECT
Remark:
N/mm
mm 0.6
1
13-12-2005 Issued for Construction
REVISION
C 333.2
% VARIABILITY
0
DATE
o
QUANTITY REQUIRED
1
REV.
VS2
CS
PIPE MATERIAL:
1. All welds to be 6mm CFW unless otherwise noted. 2. All make-up components to be supplied by the manufacturer. 3. All bottom connection material to be suited with pipe material. 4. Elevations (EL) are in mm.
NOTES:
FIG: 6
BOTTOM CONNECTION NO.:
INSTALLED LOAD:
TRAVEL (AXIAL):
1820
Node No.:
B SIZE:
MGC MGC APPD PROJ. BY ENGR
RPL RPL CLIENT
FIELD DESIGN CELL
VARIABLE SPRINGS
JOB No
DRAWING No
REV
PIPE SUPPORT STANDARD
22960
951Y-SPR-004
1
FOR MAINTNANCE (Line 951- WB- 012- 10")
SPS DRAWING
BELLOW DATASHEET
LOAD SUMMARY SHEET Reliance Engineering Associates Private Ltd. Load Summary Chart Date of Ge ne ration: File Location:
Node 10 120 130 140 170 210 220 230 240 250 260 270 580 590 600 610 640 650 660 670 680 690 805 875 960 985 990 1000 1100 1140 1220 1250 1260 1270 1299 1410 1620 1640 1650 1660 1689 1800 3010 3070 4050 4070 4120 4150 4170
14-Jan-06 c:\s tre s s out\KB038A001401141157.xls
Max. Static Fx Fy Fz -3026 -283 -689 -5500 1326 -4914 -4877 -3838 9691 3532 4123 1440 -6309 1086 713 998 745 -1011.3 -959.4 1084 279 17 662 334 2678 -90 -1484 1461 746 -876 -1472 -1786 -2088 168 -954 1262 1564 1896 2137 -240 955 -1259 1246 600 -2495 -248 -15837 16655 4653
-15458 -19172 -11710 -26565 -27275 -22514 -12546 -16219 -15425 -15003 -17525 -6118 -3048 -3479 -3097 -3515 -3056 -3371 -3198 -3614 -3285 -3298 -12263 -10434 -2340 -1900 -3195 -3008 -11349 -17708 -8969 -7238 -8217 -7976 -12798 -3049 -8812 -7262 -8183 -7980 -13120 -3067 -7833 -2164 -12491 -4676 -31157 0 -83854
-11511 814 3445 7648 6542 -967 -6954 217 2121 -4500.9 -5257.5 -1835.4 1893 -323 -8 357 -916.8 -1011.3 6 44 -16 65 3619 -3757 -532 -563 -3820 699 3322 -5240 -800 1407 -1310 -503 -3719 729 -535 1227 -1281 -493 -3818 1001 1407 304 2801 1381 -2994 21194 24722
Max. Composite Occ Fx Fy Fz -11585 -283 -647 -5109 704 -4895 -4831 -3833 50488 3531 4123 1440 -30719 1048 713 992 745 952 728 1060 279 0 4126 334 4886 -70 -1291 4403 282 -734 -1472 -1392 -1651 12594 -484 2191 1564 1604 2044 -12267 467 -1764 757 552 -2490 0 -19092 18228 2841
-12790 -13086 -13980 -23280 -23156 -18103 -11815 -13389 -12233 -11814 -13755 -4801 -2294 -3593 -2467 -3094 -2561 -2912 -2439 -3551 -986 1230 -19457 -17659 2336 -2389 -3833 -2397 -10415 -15470 -6209 -7528 -8135 -5832 -20930 -12199 -6172 -7446 -8373 -6298 -20978 -11820 -11537 -2415 -14246 1316 -11612 0 -45483
-39967 556 3174 7567 6541 -967 -28705 217 2005 -66 -10608 -14 1820 -2344 -1 2096 -36 -2186 6 1916 7 1740 3619 -8978 -510 -481 -14357 623 2670 -4307 -638 1407 -1100 -503 -3371 8028 -256 1227 -1281 -493 -3490 8638 1401 304 2801 0 -2599 22805 12902
Sustained Fx Fy Fz -147 20 299 -898 1035 -169 -95 -54 -31 -18 -11 -8 -143 -45 -15 -7 1 -839.4 1 1 4 14 -45 52 91 -76 -58 18 -39 28 -225 172 -55 -38 130 -100 234 -168 56 35 -122 95 -34 -17 -1801.8 -167 711 0 1619
-14754 -17646 -3528 -21080 -21389 -17668 -9839 -12723 -12099 -11768 -13746 -4799 -2778 -2643 -2599 -2908 -2548 -2798 -2658 -2681 -2729 -2791 -8552 -7854 -1943 -1554 -2531 -2517 -5361 -9575 -7491 -6088 -5653 -6698 -8447 -2350 -7358 -6108 -5645 -6701 -8829 -2342 -6972 -1880 -6006 -3602 -23909 0 -27407
704 519 322 223 -427 553 -22 4 -1 -3530.4 -4123.8 -1439.7 -83 29 -8 2 -1 -839.4 -1 3 -13 51 -192 164 -120 -460 220 -172 94 -179 281 -65 -22 22 -39 -38 193 -61 -20 23 -38 -39 366 -38 -1802 1068 -1135 0 -728
Fx
Design Fy Fz
-3026 -83 -689 -5500 742 -4914 -4877 -3838 9691 3532 4123 1440 -6309 1086 707 998 743 958 721 1084 222 0 662 149 2678 -69 -1484 1461 746 -876 -965 -1786 -2088 0 -954 1262 1144 1896 2137 0 955 -1259 1246 600 -2495 0 -15837 16655 4653
-8704 -635 -11710 -20273 -21947 -16628 -9512 -12808 -12077 -11774 -13745 -4799 2 -3479 -2356 -3010 -2480 -2884 -2405 -3614 -742 0 -12263 -10434 603 -1599 -3195 -925 -11349 -17708 -4179 -7151 -8217 0 -12798 -3049 -4211 -7215 -8183 0 -13120 -3067 -6263 -2132 -12206 0 -4411 0 -83854
-9998 172 3445 7648 6542 -861 -6954 193 2121 -60 -52 -14 1893 -323 -2 357 -34 -334 5 44 6 21 3619 -3161 -532 -475 -3754 699 3322 -5240 -800 1189 -1310 0 -3719 -380 -535 1045 -1209 0 -3818 89 1407 220 2680 0 -2994 21194 24722
Operating Fx Fy Fz -2474 -283 -647 -5109 704 -4895 -4831 -3833 9349 3531 4123 1440 -6087 1048 713 992 745 952 728 1060 279 0 609 334 2495 -70 -1291 977 282 -734 -1472 -1392 -1651 168 -484 668 1564 1604 2044 -240 467 -651 757 552 -2490 0 -9860 10765 2841
-9314 -2080 -10799 -20428 -21930 -16631 -9548 -12798 -12079 -11774 -13745 -4799 -210 -3402 -2378 -3002 -2485 -2877 -2426 -3534 -929 0 -12232 -10185 548 -1621 -3096 -1178 -8949 -14562 -5347 -6596 -8018 -1641 -11352 -2981 -5281 -6733 -8041 -1521 -11736 -3032 -5308 -2099 -12491 0 -8782 0 -44038
-11511 556 3174 7567 6541 -967 -6784 217 2005 -66 -56 -14 1820 -288 -1 350 -36 -322 6 37 7 17 3619 -3757 -510 -481 -3820 623 2670 -4307 -638 1407 -1100 -503 -3371 729 -256 1227 -1281 -493 -3490 1001 1401 304 2801 0 -2599 13646 12902
COMPLETED STRESS ISO
FDC PIPING
PRACTICAL SESSION DEMONSTRATION
OF CAESAR
THANK YOU!!
