CAESAR II 5.

1
Training

Vivek Paul
Engineer (Tech.)
KLG SYSTEL LTD
AGENDA
 Introduction to CAESAR II & Basic theories
 Data Inputting
 Usage of various spread sheets
 Modeling of piping system
– Modeling Miters
– Reducers

 Nozzle/Vessel Junction through C-nodes

 Rigid Elements
 Bellows
 Cold Springs
 Expansion Loop
 Hangers
 Static analysis along with wind loads
 Combining Load Cases as per codes
 Various Graphics Outputs
 Isometric generation
 Combining Dynamic Load as per code requirement
 Creating various reports (WRC 297, Loads on pumps compressors, Exchangers)
 Processing the result
Introduction to Pipe stress analysis

In order to properly design a piping system, the engineer must

understand both a system behavior under potential loading as well
as the regulatory requirements imposed upon it by governing codes.
System behavior can be quantified through the aggregate values of
numerous physical parameter like acceleration, velocities,
displacements, internal forces and moments, stress, and external
reaction developed, under applied loads. Allowable value for each of
them are set after review of appropriate failure criteria for the
system. System response and failure criteria are dependent on type
of loading which can be classified by Primary Vs Secondary,
Sustained Vs Occasional, Static Vs Dynamic.
Why do we perform Pipe Stress Analysis

 In Order to Keep stress in the Pipe & Fittings within code allowable
levels.
 In Order to keep Nozzle loading on attached equipment with in
allowable of manufactures or recognized standard (NEMA SM23,
API610, API617)
 In Order to calculate design loads for sizing supports and restraints.
 In order to determine piping displacement for interference checks
 In order to solve dynamic problems in piping, such as those due to
mechanical vibration, fluid hammer, pulsation, transient flow and
relief valve discharge
 In order to help optimize piping design.
Pipe Stress Design Data
Design Data typically required for pipe stress analysis consist of
 Pipe Material & Size
 Operating Parameter
 Temperature
 Pressure
 Fluid Contains
 Code Stress Allowable
 Loading Parameters
 Insulation Weight
 External Equipment Movement
 Wind & Earthquake criteria
But we can go ahead only when you
know this

 Basic Piping
 Isometric reading & Generation
 Piping components
CAESAR II Main Menu

After starting CAESAR II Main Menu appears, it is recommended to kept this

Window minimum as this will used only for accessing toolbar and command
File Menu
 Set Default Data Directory
– Tool to set Default project directory where all the files of particular projects will be
saved. Selection of data directory is very important as configuration, units, data files
found in the directory will be considered to be a Local to that Job
 New
– For creating a new Piping or structural files
 Open
– Open an existing piping or structural Job
 Clean up (Delete) Files
– Enables user to delete unwanted scratch, listing, input or output files to retain more
hard disk space
 Recent Piping or Recent structural Files
– Display the four most recently used Piping or structural files
 Exit
– Closes CAESAR II Application
Input Menu

 Piping
 Inputs CAESAR II Piping Model
 Underground
 Converts Existing Piping Model to buried piping
 Structural Steel
 Input CAESAR II Structural Model
Piping Input
 Data Fields
 Node Numbers
 Element Lengths
 Element Direction Cosines
 Pipe Section Properties
 Operating Conditions: Temperature & Pressure
 Special Element Information
 Boundary Conditions
 Loading Conditions
 Piping Material
 Material Elastic Properties
 Densities

 Spreadsheet Overview
 Undo/Redo
 Customize Toolbar
Necessity of Node Points
Node points are required at any location where it is necessary to provide information to,
or obtain information from pipe stress software. Node points are required to:
 Define geometry
 System Start, End, Direction Changes, Intersection etc
 Observing Changes in operating condition
 System start, isolation or pressure reduction valve
 Define element stiffness parameters
 Change in pipe cross section or material, rigid element or expansion Joints
 Defining Boundary conditions
 Restraints and imposed displacements
 Specify Mass points
 Refinement of mass modal
 Note Loading condition
 Insulation Weight
 Imposed Forces
 Earthquake g-factor
 Response spectra
 Wind Exposure & Snow
 Retrieve information from the stress analysis
 Stress at piping mid spans
 Displacements at wall penetration
Node Numbers

The FROM & TO node number defines the

starting & end of the element respectively.
Node numbers must be numeric, ranging
from 1 to 32000. Normally, the FROM node
number is "duplicated forward" by
CAESAR II from the preceding element
NAME

This check box is used to assign non-numeric

names to node points. Double-clicking this
check box activates an auxiliary spreadsheet
where names, of up to 10 characters, can be
assigned to the FROM and/or TO nodes.
These names will show up in place of the
node numbers in graphic plots and reports
ELEMENT LENGTH

Length of element is entered as a delta

dimension which are the measurement along
X, Y and Z axis. one or more entries must be
made except Zero length Expansion Joints.
Note: 3-2, -2, 2-3-3/16 are the acceptable format for Feet & Inches
Entries. Simple forms of addition, multiplication, and division
may be used as well as exponential format.
Please Answer

 6.3 =?
 6-10 =?
 6-10-1/4 =?
 6-10-1/4+3-7 =?
 6.3*12 =?
ELEMENT DIRECTION COSINE

 Direction Vector or direction

cosine which define the center
line of the element.
ELEMENT OFFSET

 Thermal expansion will be “0”

for the offset portion of an
element. No element flexibility
will be generated for offset
part at the time of analysis.
PIPE SECTION DATA

 Diameter
 Wt / Sch
 +Mill Tol %; WI
 -Mill Tol %
 Seam-Welded
 Corrosion
 Insul Thk
DIAMETER
 The Diameter field is used to specify the pipe diameter. Normally, the nominal
diameter is entered, and CAESAR II converts it to the actual outer diameter necessary
for the analysis. There are two ways to prevent this conversion: use a modified UNITS
file with the Nominal Pipe Schedules turned off, or enter diameters whose values are
off slightly from a nominal size (in English units the tolerance on diameter is 0.04 in.)

 ANSI Nominal Pipe ODs, in inches (file ap. bin)

½ ¾ 1 1 ½ 2 2 ½ 3 3 ½ 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 42

 JIS Nominal Pipe ODs, in millimeters (file jp. bin)

15 20 25 32 40 50 65 80 90 100 125 150 200 250 300 350 400 450 500 550 600 650

 DIN Nominal Pipe ODs, in millimeters (file dp. bin)

15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500 600 700 800 900 1000
1200 1400 1600 1800 2000 2200
Wt / Sch

t =t+c
m

t = minimum wall thickness, in.

m

t = minimum wall thickness required for

pressure, in
C= sum of allowances for thread or groove depth,
corrosion, erosion and manufacturer’s tolerance, in
Wt / Sch
The Wall Thickness/Schedule field is used to specify the thickness of the pipe. Normal input consists of a
schedule indicator (such as S, XS, or 40), which will be converted to the proper wall thickness by
CAESAR II. If actual thickness is entered, CAESAR II will accept it as entered. Available schedule
indicators are determined by the active piping specification, set via the configuration program. The
available schedules are listed below.

 ANSI B36.10 Steel Nominal Wall Thickness Designation:

 S - Standard
 XS - Extra Strong
 XXS - Double Extra Strong

 ANSI B36.10 Steel Pipe Numbers:

10 20 30 40 60 80 100 120 140 160

 ANSI B36.19 Stainless Steel Schedules:

5S 10S 40S 80S

 JIS PIPE SCHEDULES

 1990 Steel Schedules:
10 20 30 40 60 80 100 120 140 160
 1990 Stainless Steel Schedules:
5S 10S 40S
 DIN PIPE SCHEDULES
+Mill Tol %; Wl

The Positive Mill Tolerance is only enabled when IGE/TD/12 is

active, and is used when the Base Stress/Flexibility On
directive of the Special Execution Options is set to Plus Mill
Tolerance. In that case, piping stiffness and section modulus is
based on the nominal wall thickness, increased by this
percentage. The user may change this value on an element-by-
element basis.
If the B31.3 piping code is activated, this field is
used to specify the "weld strength reduction
factor" (Wl), to be used in the minimum wall
calculation for straight pipe.
-Mill Tol %

The Negative Mill Tolerance is read in from the

configuration file for use in minimum wall thickness
calculations. Also, for IGE/TD/12, this value is used
when the Base Stress/Flexibility On directive of the
Special Execution Options is set to Plus Mill
Tolerance. In that case, piping stiffness and section
modulus is based on the nominal wall thickness,
decreased by this percentage. The user may change
this value on an element-by-element basis.
SEAM-WELDED

If the B31.3 piping code is active, the "seam-

welded" check box is used to activate the Wl
field. The Wl field is the "weld strength
reduction factor" used to determine the
minimum wall thickness of the element.
CORROSION

Enter the corrosion allowance to be used order

to calculate a reduced section modulus. A
"setup file" directive is available to consider
all stress cases as corroded
Insul Thk ()

Enter the thickness of the insulation to be applied to the

piping. Insulation applied to the outside of the pipe
will be included in the dead weight of the system,
and in the projected pipe area used for wind load
computations. If a negative value is entered for the
insulation thickness, the program will model
refractory lined pipe. The thickness will be assumed
to be the thickness of the refractory, inside the pipe.
OPERATING CONDITION

 Temperature
 Pressure
TEMPERATURE

CAESAR II uses these temperatures to obtain the thermal strain and allowable stresses for the element from
the Material Database. Thermal strain can be specified directly as well. thermal strain have absolute
values on the order of 0.002 and are unit less. CAESAR II uses an ambient temperature of 70 F, unless
changed using the special execution parameter option.

There are nine temperature fields, to allow up to nine different operating cases. Temperature values are
checked (by the error checker) to insure they are within the code allowed ranges. Users can exceed the
code ranges by entering the expansion coefficient in the temperature field in units of length/length. The
expansion coefficient can be a useful method of modeling cold spring effects. Also when material 21(user-
defined material) enter temperature *expansion coefficient as in the example below.
Values entered in the temperature field whose absolute values are less than the Alpha Tolerance are
taken to be thermal expansion coefficients, where the Alpha Tolerance is a configuration file
parameter and is taken to be 0.05 by default. For example, if the user wanted to enter the thermal
expansion coefficient equivalent to 11.37in./100ft., the calculation would be:

11.37in./100ft. * 1 ft./ 12in. = .009475 in./in.

This would be entered into the appropriate Temperature field.

PRESSURE
There are ten pressure fields, to allow up to nine operating, and one hydro
test, pressure cases. When multiple pressures are entered, the user
should be particularly careful with the set up of the analysis load
cases, and should inspect CAESAR II's recommendations carefully
before proceeding.

Access to operating pressures 3 through 9 is granted through the

Extended Operating Conditions input screen, accessible via the
Ellipses Dots button directly to the right of the standard Temperature
and Pressure input fields. This dialog box may be retained open or
closed at the convenience of the user.

Entering a value in the Hydro Press field signals CAESAR II to

recommend a Hydro test load case.
COMPONENT INFORMATION

 Bend
 Rigid Element
 Expansion Joint
 Reducer
 SIF & Tees
Bend
If element described by input sheet ends with bend, elbow, mitered joint bend
check box to be checked.
– Bend angle is always defined by element entering and leaving the bend.
– By default the bend radius (Basically it is long radius) is 1.5 times of Pipe nominal
diameter.
– CAESAR II automatically creates two nodes on bend at 0 degree location and bend
mid point. (Bend)
– TO node of the element entering the bend located at far point on the bend. This is for
stress and displacement output. Far point is the weld line of bend and adjacent to
element leaving the bend.
– 0 degree Node will not be created if Total length of element specified is equal to R
tan(β/2)
– Nodes on bend curvature can not be place closer together then specified
angle in CONFIG/SETUP File.
– Minimum and Maximum bend angle also need to be specified in
CONFIG/SETUP File only.
BEND- TYPE

For most codes, this refers to the number of attached

flanges, and can be selected from the drop list. If
there are no flanges on the bend then leave the
Type field blank. It has been seen that elbows tends
to ovalize during bending.
– Single & Double flanged bends can be enter by entering 1
or 2 respectively for the type.
– When specifying single flanged bends it does not matter
which end of bend the flange is installed
– If user wants to include the weight of rigid flange then he
has to put rigid element with equal length of flange on
desired side of bend.
Some practice

 45 degree elbow
 U type/180° return bend
 Circular ring
Mitered Bends

A Miter Joint is a change in pipe direction

through proper cutting and welding of straight
pipe.

 Closely Spaced
 Widely Spaced
– R = r[1 + cotθ]
2
FITTING THICKNESS

 Thickness of the bend will be changed

without affecting preceding & following pipe
 CAESAR applies this change on current
bend only
 As per B31 Stress at elbow are calculated on
basis of section modulus of matching pipe
however the stress intensification factor &
Flexibility factor for bend is based on wall
thickness of elbow.
K-FACTOR

K-Factor shows flexibility of bend w.r.t same

length of pipe. If K-factor value is 1.5, it
means bend is 1.5 times as flexible as same
length of pipe. Bend flexibility factor are
calculated as per code but user can overwrite
it.
RESTRAINTS

Restraints we are using to provide boundary condition.

 Anchor
 Double Acting & Single Acting – Transitional/Rotational
 Guide
 LIM
 XSNB, YSNB, ZSNB
 X2, Y2, Z2
 K2
 XSPR, YSPR, ZSPR
 X (cosx, cosy, cosz) or X (vecx, vecy, vecz)
 RX (cosx, cosy, cosz) or RX (vecx, vecy, vecz)
 XROD, YROD, ZROD
ANCHORS

Anchors is an rigid element hence displace should not

be defined at an anchor node.
For anchors with displacement following point should
be considered
 Enter only displacement for the node
 Do not apply any restraint or anchors at the node to
be displaced
 All 6 degree of freedom at the node should be
defined.
 Leaving the displacement field blank will default to
zero.
DOUBLE ACTING RESTRAINT

 Transitional
 Rotational
SINGLE ACTING RESTRAINT

 Always gives information about Free Axis

 Can be defined along +ve, -ve & skewed axis
 If CNode left blank then the restrained node
is connected via the restraint stiffness to a
rigid point in space. If the CNode is entered
then the restrained node is connected via the
restrained stiffness to the connecting node
GUIDE Double Acting

 Guided pipe in the horizontal or skewed

direction will have a single restraint, acting in
the horizontal plane, orthogonal to the axis of
the pipe.
 A guided vertical pipe will have both X & Z
direction supports
DIRECTIONAL LIMIT STOPS

Limit stops are single pr double acting restraint

whose line of action is along the axis of the
pipe, these restraint can have gaps which
permits free movement along the restraint
line of action.
– Directional Limit stop with gap
– Two limit stops acting in opposite direction
WINDOW

 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 orthogonal to the
pipe axis
ROTATIONAL DIRECTIONAL RESTRAINT

These restraints can be considered specialty

items and are typically only used in
sophisticated expansion joints or hinge
models.
– Bidirectional rotational restraint with Gap
– Hinged Assembly with directional rotational
restraint
Single-Directional restraint with
predefined displacement
Single-Directional restraint and Guide
with Gap and Predefined Displacement
RESTRAINT ON BEND AT 45 DEGREES
RESTRAINT ON BEND AT 30 & 60 DEG
Vertical Dummy Leg On Bends
Reducer
Load Case Editor

 Scale Factor for load components

When building load cases, load components (W,T1,D1,WIND1
etc.) may be preceded by scale factors such as 2.0, -, 0.5 etc.
 One loading is multiple of other
 Loading may be directionally reversible (i.e. wind or earthquake), “+”
& “-” will be used to specifydirection
1.5W+1.1T1+1.1D1+1.25Wind1
User defined load case names

Note: Load case name should not exceed 132 characters

User-controlled combination methods

 Algebraic
 Scalar
 SRSS
 Abs
 Max
 Min
 Sign Max
 Sign Min
Algebraic

This method combines the displacement, forces,

moments, restraint loads and pressures of the
designated load cases in an algebraic (vectorial)
manner. The resultant forces, moments, and
pressures are then used (along with the SIFs and
element cross-sectional parameters) to calculate the
piping stresses. New combination cases
automatically default to this method, unless
specifically designated by user.
SCALAR

This method combines the displacement,

forces, moments, restraint loads and stresses
of the designated load cases in a scalar
manner but retaining consideration of sign.
This method might typically be used when
adding “plus” or “minus” seismic loads to an
operating case, or when doing an occasional
stress code check.
SRSS

This method combines the displacements,

forces, moments, restraint loads and stresses
of defined load cases in Square root of the
sum of the squares manner; however due
to squaring “-ve” vs. “+ve” values yield no
difference. This load typically used when
combining seismic loads acting in orthogonal
directions.
Abs

This method combines the displacements, forces,

moments, restraint loads and stresses of defined
load cases in Absolute manner; however due
absolute values used by the combination method “-
ve” & “+ve” values yield no difference in the results.
This load typically used when combining loads acting
in orthogonal directions. This method may be used
when doing an occasional stress code check (i.e.
absolute summation of the sustained and occasional
stresses)
MAX

For each result value, this method selects the

displacement, force, moments, restraints load, and
stress having the largest absolute value from the
designated load cases; so no actual combination, per
se, takes place. Load case results are multiplied by
any scale factor prior to doing the selection of
MAXIMA. This method is typically used when design
case (worst loads, stress etc.) from number of loads.
MIN

For each result value, this method selects the

displacement, force, moments, restraints
load, and stress having the smallest absolute
value from the designated load cases; so no
actual combination, per se, takes place. Load
case results are multiplied by any scale factor
prior to doing the selection of MINIMA.
Sign MAX

For each result value, this method selects the

displacement, force, moments, restraints load, and
stress having the largest actual value considering the
sign from the designated load cases; so no actual
combination, per se, takes place. Load case results
are multiplied by any scale factor prior to doing the
selection of MAXIMA. This method is typically used
in conjunction with the SignMin method to find the
design range for each value (i.e. maximum positive
and maximum negative restraint loads)
SignMin

For each result value, this method selects the

displacement, force, moments, restraints load, and
stress having the Smallest actual value considering
the sign from the designated load cases; so no
actual combination, per se, takes place. Load case
results are multiplied by any scale factor prior to
doing the selection of MAXIMA. This method is
typically used in conjunction with the SignMax
method to find the design range for each value (i.e.
maximum positive and maximum negative restraint
loads)