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CAESAR II Applications Guide

Hexagon Documentation

Generated 08/10/2023

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Overview
Refer to this guide for tutorials of complete systems and examples of specific piping
components.

Tutorial A and Tutorial B show the modeling and analysis workflows of a complete system.
Work through the tutorials if you have not previously used CAESAR II.

Use the following techniques and methods to model individual piping components:

Bends

Restraints

Hangers

Expansion Joints

Examples illustrate the use of CAESAR II for piping problems, seldom-used components, or
unusual geometries.

Customer Support
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Documentation updates available from Hexagon PPM Documentation <https://docs.hexagonppm.com>
Published: 8/31/2022 at 5:54 PM

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Tutorial A - Create a typical piping system

This tutorial provides step-by-step instructions for defining a typical piping system, analyzing
flexibility and stresses, and reporting results. This process includes:

Creation and entry of the pipe stress model.

Analysis and evaluation of the results.

Redesign of the system (as covered in Tutorial B - Check equipment and redesign a
piping system).

The piping system you will model defines part of a refining process that moves crude from the
bottom pump to a steam stripper unit. The end suction top discharge pump has a 10-inch
suction nozzle and an 8-inch discharge nozzle. The 8-inch line runs through a check valve
with a 6-inch bypass to a spring hanger support. The 8-inch line then runs over a hard support
before entering the vertical vessel.

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The boundaries of the system are the pump discharge nozzle (on the right) and the vessel
nozzle (on the left). The pump nozzle is a satisfactory boundary because the movement of
that point (as the pump heats up in operation) is known and easily calculated from the thermal
strain between the pump nozzle and the base point. The vessel nozzle is an adequate
boundary because of the known thermal growth of the vessel and the greater stiffness of the
vessel with respect to the 8-inch pipe.

You can take an opposite approach by modeling the pipe ends to immovable points,
such as the vessel foundation and the pump support (or base) point.

When you require a more accurate model for supporting structures, you can include
structural steel in the model.

The check valve sits on top of the welding tee for the 6-inch bypass piping. The 6-inch line
runs through a gate valve before reentering the 8-inch line through a second welding tee
above the check valve. The total weight and length of this valve assembly is unknown.
Because of this, the valve lengths and weights are pulled from the CAESAR II generic
database.

The spring hanger above this valve assembly carries the deadweight and absorbs the thermal
growth of the vertical pipe run. The hanger attaches to the elbow in line with the vertical pipe
at the near end of the elbow. The hanger is quite sensitive to the weights used. The difference
between the actual installed valve weights and modeled weights should be used to adjust the
spring preload. In Tutorial B you will verify that the hot load on the spring is toward the center
of the manufacturer's recommended spring working range to allow errors in load estimation.
An appreciable change in these weights requires reanalysis of the system.

The weld point on the vertical run of the elbow is the near end and the horizontal run
weld point is the far end.

The other end of the hanger attaches to available structure above the model. Because
of the vertical thermal growth of the hanger attachment point, you cannot use a simple
rod hanger.

The horizontal piping rests on an unspecified support at the far end of the next elbow.
This support, modeled as a rigid nonlinear restraint acting on the pipe centerline, allows

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the piping to move upward but prevents downward motion.

1. Review the piping system drawing

2. Configure the software

3. Define the first pipe element

4. Define the vertical pipe run

5. Define the horizontal pipe run

6. Define the 6-inch bypass

7. Review the piping input

8. Check for errors

9. Check the static load cases

10. Run the static analysis

11. Review the graphical analysis results

12. Review the static output reports

13. Conclusions

Review the piping system drawing

The following drawing contains the detail you need to construct the model.

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You will assign node numbers where there is:

A change in geometry, such as a pipe diameter or wall thickness.

A change in direction, materials, temperature, or pressure operating conditions.

The application of boundary conditions such as restraints, point loads, and

displacements.

Any other location for which you want output.

Node numbering increments by fives, starting with node 5 at the pump nozzle. The 6-inch
bypass piping uses the same progression, but starts with node 600. The software uses the
nodes to analyze the piping stress.

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Output for each elbow is available for nodes at the near, mid, and far points of a bend (at 0,
45, and 90-degrees).

Configure the software

Open CAESAR II from the Windows Start menu.

The CAESAR II main window displays.

1. In the main CAESAR II window ribbon, click Home > Setup > Configure .

The CAESAR II Configuration Editor displays.

2. Set the numeric increment between nodes, using an increment of 5 between node
numbers. The default increment is 10, so you must change it.

Click the Geometry Directives category, and then select 5 in the Auto Node Number
Increment list.

3. Click Save and Exit .

The software saves the change, closes the CAESAR II Configuration Editor, and
returns to the main CAESAR II window.

4. In the main window ribbon, click Home > New .

The New Job Name Specification dialog box displays.

5. Type Tutor-A as the file name. The default folder is C:\ProgramData\Intergraph

CAS\CAESAR II\<version number>\Examples. You can click Browse to navigate to

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another folder.

C:\ProgramData is a hidden folder.

6. Click OK.

The software saves the job file, closes the New Job Name Specification dialog box,
and displays the Review Current Units dialog box with the English units used for all
piping element fields.

7. Click OK to close the Review Current Units dialog box and return to the main CAESAR
II window.

Define the first pipe element

Periodically click Save or File > Save as you create elements. CAESAR II also
interrupts your session and prompts you to save your work 30 minutes after the last save.

Node 5-10 Pipe Element

The first pipe element runs from the pump

discharge nozzle (node 5) to the centerline
intersection of the 8-inch main line with the 6-
inch bypass (node 10). The length of this
element is 2 ft. in the Y direction.

1. In the main window ribbon, click Home > Input > Piping Input .

Because this is a new job, the Review Current Units dialog box again displays. Click
OK to close it. A new window with command toolbars, the Classic Piping Input dialog
box, and a graphic view displays.

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CAESAR II automatically generates the From and To nodes when you start a new
piping element. The From box displays 5 and the To box displays 10 because you set
the node increment to 5 in the CAESAR II Configuration Editor dialog box. The default
-Mill Tol % value for the piping code also displays.
The graphics view displays and updates your piping system as you define element
properties.

2. In the DY box, type 2- to specify the element length of 2 ft.

The dash ( - ) symbol indicates feet. If you type a length without the dash, the
units are inches.

3. In the Diameter box, type 8 to specify the nominal pipe size of 8 in.

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The software replaces the nominal value with the actual outer diameter (OD) of 8.6250
in. The pipe element updates in the graphic view.

4. In the Wt/Sch box, type S to specify standard wall thickness in inches.

The software replaces S with the actual wall thickness of 0.3220 in.

5. Type the following values:

Corrosion 0.0313 (the corrosion allowance in inches)

Temp 1 600 (the maximum operating temperature

in degrees F)

Pressure 1 30 (the maximum incidental pressure in

lb./sq.in.)

6. In the Fluid Density box, type 0.8SG to specify the specific gravity of 80 percent of the
deadweight of water.

The software replaces the specific gravity with the fluid density of 0.02889 lb./cu.in.

7. In the Material list, select (1)LOW CARBON as the pipe material.

The software queries the material database and adds values for Elastic Modulus,
Poisson’s Ratio, and Pipe Den. The software also references the material number to
add the coefficient of expansion for the specified temperatures.

8. In the Insul Thk box, type 3 to specify the insulation thickness in inches. In the
Insulation Density list, select Calcium Silicate.

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The software replaces the insulation material type with the insulation density of 0.00666
lb./cu.in.

Optionally, type 11.5/1728 in the Insulation Density box. 11.5 is the density in
lb./cu.ft. 1728 is the factor (123) to convert the density to lb./cu.in. Numeric fields allow
simple math.

9. Double-click the Displacements check box to display the Displacement tab on the
right.

5 displays as the value for Node 1.

10. Define displacements for the thermal growth of the pump discharge nozzle from the
base support (anchor) point. For anchor displacement DY in the Vector 1 column, type
0.077. For anchor displacement DZ in the Vector 1 column, type 0.046.

The displacement vector displays in the graphic view.

11. Type 0 for the other four degrees of freedom (DX, RX, RY, and RZ).

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If you do not assign values for DX, RX, RY, and RZ, then node 5 is free to
move in these directions.

12. Double-click the Allowable Stress check box to display the Allowable Stress tab on
the right.

13. In the Code list, select B31.3 if it is not the default selection.

14. Type the following values:

SC 20000 (the cold allowable stress in psi)

SH1 17300 (the hot allowable stress in psi)

(1)LOW CARBON is a generic material without associated allowable stress

values in the material database. You must manually define allowable stresses.

Do not use commas when typing allowable stress values. You can use an
exponential format, such as 20e3.

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You now have the following material property and allowable stress values defined:

If a job is new, CAESAR II first opens the Review Current Units dialog box. For an
existing job, the Classic Piping Input dialog box opens directly with the first piping
element active.

If the Units File Label box on the Review Current Units dialog box does not show
Imperial units, click Cancel, and then select Tools > Configure Setup. Click the
Database Definitions category and select English in the Units File Name list.

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Define the vertical pipe run

Node 10 Welding Tee Intersection

Node 10 defines the bottom intersection of the

8-inch main and 6-inch bypass lines. This
intersection is constructed using an 8 x 6
welding tee. Piping codes recognize the
reduced strength of this piping component by
increasing the calculated stress at this point
in the system. For CAESAR II to include this
stress intensification factor in the stress
calculation, the node must be identified as a
welding tee.

1. Double-click the SIFs & Tees check box to display the SIFs/Tees tab on the right.

2. In the Node box, specify 10 as the intersection node.

3. In the Type list, select 3 - Welding.

CAESAR II calculates the SIFs at this intersection according to the selected B31.3
piping code.

Node 10-15 Pipe Element for Welding Tee

This element runs from the intersection point

(node 10) to the beginning of the check valve
(node 15). This short run finishes out the
welding tee. The length of the element is 7
inches in the Y direction.

1. Click Continue on the Navigation Tools toolbar to define the next length of pipe.

You can also press ALT-C or click Edit > Continue.

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The To node 10 of the previous element now displays as the From node. The To node
is 15. All pipe material properties carry forward from the previous element. Allowable
stress data also carries forward, even though the Allowable Stress box is cleared.

2. In the DY box, type 7 to specify the element length of 7 in. Press TAB.

Do not select Allowable Stress unless you have a change in material, code, or
temperature.

Uniform Loads and Wind also carry forward without selecting the check box. No other
component information, boundary conditions, or loading conditions carry forward.

Node 15-20 Check Valve

The next element is the flanged check valve

and the mating flanges. The software
considers a valve to be a rigid element and
includes the mating flanges because flange
piping components are stiffer than the
attached pipe. The software accesses the
valve/flange database to automatically
generate the valve and its data.

1. Click Continue on the Navigation Tools toolbar.

The To node 15 of the previous element now displays as the From node. The To node
is 20.

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2. Click Model > Valve, or click Valve/Flange Database on the Input Tools toolbar.

The Valve and Flange Database dialog box displays.

3. Select CHECK from the Rigid Type list and FLG from the End Type list. Click OK.

A 150 psi class flanged check valve displays between nodes 15 and 20.

The software adds valve data to the Classic Piping Input dialog box. The element
length DY is 2 ft. 3.75 in., Rigid is selected, and the weight of the valve and flanges of
470.000 displays in the Rigids tab.

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If you know the length and weight of the valve, you can directly specify the DY length
and the Rigid Weight in the Rigids tab.

If the Valve and Flange Database dialog box does not display, see Configuration Editor
in the CAESAR II User's Guide.

Node 20-25 Pipe Element for Welding Tee

This element runs from the end of the check

valve (node 20) to the top intersection point
(node 25) This short run finishes out the top
welding tee. The length of this element is 7
inches in the Y direction (half of the total
length of the 8-inch x 6-inch welding tee).

1. Click Continue on the Navigation Tools toolbar.

The To node 20 of the previous element now displays as the From node. The To node
is 25.

2. In the DY box, type 7 to specify the element length of 7 in.

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Node 25 Welding Tee Intersection

Node 25 defines the top intersection of the 8-

inch main and 6-inch bypass lines. This
intersection is constructed using a second 8-
inch x 6-inch welding tee that sits on top of
the check valve.

1. Double-click the SIFs & Tees check box to display the SIFs/Tees tab on the right.

2. In the Node box, specify 25 as the intersection node.

3. In the Type list, select 3 - Welding.

CAESAR II calculates the SIFs at this intersection according to the selected B31.3
piping code.

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Node 25-30 Pipe Element

The next element runs from the top

intersection of the 8-inch main and 6-inch
bypass lines (node 25) to the intersection of
the vertical pipe centerline and the horizontal
pipe centerline (node 30). The length of this
element is 10 ft. 2 in. in the Y direction.

Node 30 does not remain at this

location on the piping system. Any additional
input specified at 30 and all output for node 30
is located at the far weld point of the elbow,
which connects the vertical and horizontal
runs.

1. Click Continue on the Navigation Tools toolbar.

The To node 25 of the previous element now displays as the From node. The To node
is 30.

2. In the DY box, type 10- 2 to specify the element length of 10 ft. 2 in. Press TAB.

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Define the horizontal pipe run

Node 30 Elbow and Hanger

Node 30 defines the 90-degree elbow and the

hanger as the pipe run turns from vertical to
horizontal. When you define the elbow, the
software adds nodes at the elbow near point
and far point.

1. Double-click the Bend check box to display the Bends tab on the right.

The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node
28 at the elbow near point (Angle 2 of 0.000), and node 29 at the midpoint (Angle 1 of
M). Node 30 moves to the elbow far point.

The elbow is part of the vertical pipe run, but does not display until you create
the horizontal pipe run.

2. Double-click the Hangers check box to display the Hangers tab on the right.

3. Type 28 in the Node box to place the hanger at the elbow near point.

4. Clear the Allow Short Range Springs box. Use the default value of 1 - ANVIL for
Hanger Table.

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You can change the Radius value on the Bends tab.

For the first iteration of the analysis, you will use the default hanger settings with no
additional design data. Click in a hanger setting box on the Hangers tab and press F1
to open the help for more information.

A short-range spring is not used at this point because a mid-range spring is usually less
expensive.

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Node 35-40 Pipe Element

The next element starts the horizontal pipe

run in the X direction from the far point of the
vertical elbow (node 30) to the intersection of
the horizontal pipe centerlines at the
horizontal bend (node 35).

1. Click Continue on the Navigation Tools toolbar.

The To node 30 of the previous element now displays as the From node. The To node
is 35.

2. In the DX box, type -12 ft., and then press TAB.

The elbow on the vertical pipe element and the new horizontal pipe element display.

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Node 35 Elbow and Restraint

Node 35 defines the horizontal 90-degree

elbow and the rigid restraint. When you define
the elbow, the software adds nodes at the
elbow near point and far point. The length is
12 ft.

The restraint is non-linear, meaning its

stiffness is not constant but is a function of
load or displacement. It does not allow the
pipe to move downward, but allows the pipe to
move upward.

1. Double-click the Bend check box to display the Bends tab on the right.

The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node
33 at the elbow near point (Angle 2 of 0.000), and node 34 at the midpoint (Angle 1 of
M). Node 35 moves to the elbow far point.
.

Similar to the first elbow, the elbow is part of the horizontal pipe run, but does
not display until you create the next pipe element.

2. Double-click the Restraints box to display the Restraints tab on the right.

3. Type +Y in the Type box to place the support at the elbow far point.

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With no stiffness specified with the restraint, CAESAR II sets the restraint as very stiff
(rigid). This means that under any practical load, the pipe does not push the restraint
downward. The restraint displays as a vector.

The software represents all restraints, except anchors, as vectors.

You can specify up to four restraints on the Restraints tab.

To restrain lateral motion at node 35, use an X value to define a second guide restraint.

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Node 35-40 Pipe Element

The next element finishes the horizontal pipe

run in the Z direction from the far point of the
horizontal elbow (node 35) to the termination
at the intersection with the vessel wall (node
40). The length is 18 ft.

1. Click Continue on the Navigation Tools toolbar.

The To node 35 of the previous element now displays as the From node. The To node
is 40.

2. In the DZ box, type 18-, and then press TAB.

The horizontal elbow and the new horizontal pipe element display.

3. Double-click the Displacements check box to display the Displacement tab on the
right.

40 displays as the value for Node 1.

4. Define displacements for the thermal growth of the vessel nozzle. In the Vector 1
column, type the following values:

DX 0.0

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DY 0.28

DZ -0.1

RX, RY, & RZ 0.0

The displacement vector displays in the graphic view.

Define the 6-inch bypass

You now return to the 6-inch bypass piping around the 8-inch check valve above the pump.
The welding tee nodes of 10 and 25 are defined as reducing tees when you model the 6-inch
piping elements. Start the bypass from node 10 and create elements with 600-series nodes.

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Node 10-605 Pipe Element

The first element of the bypass runs from the

reducing tee at node 10 to the intersection of
the horizontal pipe centerline and the vertical
pipe centerline (node 605). The length of the
element is 2 ft.

1. Click Continue on the Navigation Tools toolbar.

The To node displays 40 and the From node displays 45. The software assumes that
you want to continue modeling from the last-created node.

2. Type 10 in the From node box and type 605 in the To node box.

3. In the DX box, type -2-. The software measures the element length from the 8-inch
centerline to the centerline of the vertical 6-inch line.

4. In the Diameter box, type 6 to specify the nominal pipe size of 6 in.

The software replaces the nominal value with the actual outer diameter (OD) of 6.6250
in.

5. In the Wt/Sch box, type S to specify standard wall thickness in inches.

The software replaces S with the actual wall thickness of 0.2800 in.

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Node 605 Elbow

Node 605 defines the first 90-degree elbow of

the bypass. The software adds nodes at the
elbow near point and far point.

1. Double-click the Bend check box to display the Bends tab on the right.

The software creates a long radius elbow (1-1/2 times the nominal pipe diameter) for the
6-inch line, node 603 at the elbow near point (Angle 2 of 0.000), and node 604 at the
midpoint (Angle 1 of M). Node 605 moves to the elbow far point.

2. In the Type list, select 1 -Single Flange.

Similar to the previous elbows, the elbow does not display until you create the
next pipe element.

Each elbow on the bypass is flanged on the end closest to the gate valve. The flange acts
like a stiffening ring, reducing the bending flexibility of the elbow. This characteristic of flanged
elbows is addressed by the piping codes through a modification of the flexibility factor and
stress intensification for the elbow.

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Node 605-610 Pipe Element

This short element runs from the far point of

the elbow (node 605) to the beginning of the
bypass gate valve (node 610).

1. Click Continue on the Navigation Tools toolbar.

The To node displays 610 and the From node displays 605.

2. In the DY box, type 9 to specify the element length of 9 in.

The horizontal elbow and the new horizontal pipe element display.
The 9-inch length puts node 610 at the far end of the bend. The locations of
nodes 605 and 610 are coincident. To prevent a zero-length element, the software
attaches an element length of 0.45 in., equal to 1 percent of the bend radius.

You can change the default 1percent attachment length by specifying a new value for
Bend Length Attachment Percent in Tools > Configure/Setup .

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Node 610-615 Gate Valve

This element is the 6-inch 150-psi class

flanged gate valve.

1. Click Continue on the Navigation Tools toolbar.

The To node displays 615 and the From node displays 610.

2. Click Valve/Flange Database on the Input Tools toolbar.

The Valve and Flange Database dialog box displays.

3. Select GATE from the Rigid Type list and FLG from the End Type list. Click OK.

A 150 psi class flanged gate valve displays.

The software adds valve data to the Classic Piping Input dialog box. The element
length DY is 1 ft. 5.750 in., Rigid is selected, and the weight of the valve and flanges of
225.000 displays in the Rigids tab. The software includes these values in the analysis.

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Select NOFLG in the End Type list of the Valve and Flange Database dialog box if you
do not want to include the deadweight and length of the attached flanges in the analysis.

Node 615-620 Pipe Element and Node 620 Elbow

This element runs from the end of the gate

valve (node 615) to the top horizontal pipe
centerline and the vertical pipe centerline
(node 620).

You need to find the Y distance between

nodes 615 and 620, where 620 is at the same
height as the top welding tee node 25.

1. Click Distance on the Input Tools toolbar.

The Distance dialog box displays.

2. Select Between Element Nodes and To and From Nodes, type 615 and 25 as the
nodes, and then click Calculate.

1' 3" displays as the needed DY distance.

3. Click Continue on the Navigation Tools toolbar.

The To node displays 620 and the From node displays 615.

4. In the DY box, type 15 to specify the element length of 1 ft. 3 in.

5. Double-click the Bend check box to display the Bends tab on the right.

The software creates a long radius elbow (1-1/2 times the nominal pipe diameter) for the
6-inch line, node 618 at the elbow near point (Angle 2 of 0.000), and node 619 at the

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midpoint (Angle 1 of M). Node 620 moves to the elbow far point.

6. In the Type list, select 1 -Single Flange.

Similar to the previous elbows, the elbow does not display until you create the
next pipe element.

Node 620-25 Pipe Element Closing the Bypass Loop

This element runs from the far point of the top

bypass elbow to the reducing tee at node 25,
returning the 6-inch pipe to the 8-inch pipe
and closing the bypass loop.

1. Click Continue on the Navigation Tools toolbar.

The To node displays 625 and the From node displays 620.

2. Type 25 in the To node box.

3. Click Close Loop on the Input Tools toolbar.

The software creates the element and displays the length of 2 ft. in the DX box.

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4. To save the model click Save or File > Save.

5. Click Distance . Select Between Element Nodes, type 5 (the first element) and 40
(the last element) in the boxes, and then click Calculate. In Results, the length should
be 26' 8 3/8". Write down this value for later comparison in Tutorial B.

Your model is complete!

Review the piping input

You can review the values in your model graphically or by viewing a list of piping input data.

Review Graphically

You built your model using the default piping input layout, with a graphic view displaying to the
right of the Classic Piping Input dialog box. The size of the graphic view can be increased by
clicking Auto Hide in the upper right corner of the Classic Piping Input.

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To display the node numbers, click Node Numbers on the Plot Tools toolbar, or press N.

Click Orbit on the Standard Operators toolbar, and then use the arrow keys to rotate the
plot. You can also use the arrow keys or mouse to pan the plot after clicking Pan . Scrolling
the mouse zooms the model and pressing the center mouse button pans the plot. Clicking the
right mouse button, and then clicking Operators > Pan from the pop-up menu provides an
alternative method of panning the plot. The model then follows the cursor. The plus sign (+)
zooms in and the minus sign (-) zooms out. There are toolbar buttons and menu items to alter
the pan view and to display element and restraint information on the plot. Use these different
items to become familiar with them. To reset the plot to the default, click Reset on the Reset
toolbar or click View > Reset. To print a copy of the display, click File > Print or click Print
on the Standard toolbar.

Because the graphics are included in the input processor, the graphic must be
clicked to set the focus before printing.

The V key toggles different views. The volume plot shown below is especially useful for larger
models because it uses less of the computer's resources.

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The illustration below shows a view down the Z-axis with a zoom and pan to show the pipe
valves. This volume plot shows the nodes and identifies the tees. To see the displacements
specified in the model, click Displacements or Options > Displacements.

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Review using List

Click List Input or Edit > List to quickly review and edit different categories of data in the
job. Clicking on the row number to the left of a line of data highlights the entire row. Hold the
Shift key while clicking on a second row of data to highlight all rows in between the two.
Different types of data sets are available by choosing the appropriate tab along the bottom of
the dialog box. Use the scroll bar along the bottom of the list to view more element data such
as temperatures and pressures. The Element list is shown in the following figure.

Check for errors

1. Click Start Run to run the CAESAR II Error Checker.

CAESAR II checks the job for errors and lists a variety of notes and warnings. Error
checking generates three notes and one warning for the tutorial model. Two notes
address the hanger in the model, and the third one is the center of gravity report. The
warning addresses insulation thickness. The notes indicate that the software must
analyze and size the hanger.

The software builds the intermediate (scratch) files for the static analysis and saves binary
data for this model with the file extension ._a. With the scratch files created, the input process
is complete.

An analysis may proceed with notes and warnings, but fatal errors must be corrected
before continuing.

Check the static load cases

After error checking the model, review the load cases.

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1. Click Edit Static Load Cases on the CAESAR II Tools toolbar, or click Edit > Edit
Static Load Cases.

The Static Analysis - Load Case Editor dialog box displays.

CAESAR II begins with a standard set of load cases based upon the piping code
selected and the loads defined in input. For this tutorial, the software includes load
cases to size the hanger before performing the standard structural and stress analyses.
The hanger sizing algorithm requires two analyses before analyzing the standard load
cases:

The operating condition for this analysis consists of the dead weight of the pipe, its contents
and insulation, the design temperature and pressure, and the preload on the hanger at node
28. The installed condition includes the dead weight and hanger preload. In addition to these
structural analyses, certain stress conditions must be addressed.

For the piping code, the sustained and expansion stresses must be calculated. Sustained
stresses include dead weight, preloads, and pressure. Sustained stresses can be taken from
the installed condition analysis if the pressure loads are included. CAESAR II includes the
pressure term in the installed case because pressure, in most cases, has no impact on the
structural loads on the piping. With the installed case structural analysis also serving as the
sustained case stress analysis, no additional load case must be added to calculate the
sustained stresses.

Expansion stresses reflect the change in system position from its installed position to its
operating position. Because of system non-linearity, this change in position cannot be
determined by analyzing thermal loads alone.

By default, CAESAR II constructs a third load case to calculate the expansion stress (range).
This case is not a third, complete analysis of the system. Instead, it is a product of the
operating and installed structural analyses already performed. The difference in system
displacements between these two cases is the displacements stress range from which the
expansion stresses are calculated. The third class of stress in piping – occasional stresses

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(as opposed to expansion and sustained) – is not included in the recommended analyses and
must be specified by you. Likewise, Fatigue (FAT) stress cases are provided only when
specifically required by the active piping code (TD/12, for example).

For most systems, the recommended load cases are exactly what you want to analyze.

L1 (W) - Weight for hanger loads

Calculates the dead weight carried by the proposed spring at node 28.

L2 (W+D1+T1+P1) - Operating for hanger travel

Calculates the vertical travel of the proposed spring. All load categories, which compose the
operating load case, are used for this analysis. These are dead weight, displacements,
thermal set 1, and pressure set 1. With these two numbers—the load carried by the hanger
and the amount of travel it must accommodate—The software selects the appropriate spring
from the Anvil catalog. This spring and its proper preload are installed in the model for the
remaining analyses.

L3 (W+D1+T1+P1+H) - Operating case condition 1

Defines the operating hanger load case. L3 is identical to L2 but includes the sized hanger
preload (H). This analysis produces the operating forces and moments on the supports, and
the deflections of all points in the system. L3 is a structural analysis case and not a B31.3
stress analysis case. The refining piping code does not recognize pipe stress in the operating
condition as a test for system failure and does not establish a limit for this state of stress.

L4 (W+P1+H) Alternate sustained stress based on operating condition 1

Provides an alternate method for the sustained case of L5, using the restraint status from the
L3 operating load case to evaluate the stresses induced by primary loads.

L5 (W+P1+H) - Sustained case condition 1

Defines a structural and stress case of a cold system. The load case eliminates the
(assumed) thermal effects (D1+T1). By including pressure (P1), this case also has the
necessary components to be used to report the system’s sustained stresses.

L6 (L3-L5) - Expansion case condition 1

Defines an algebraic combination of two basic load cases. The displacements of L5 are
subtracted from the displacements of L3 to produce these results. This case develops the

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displacement range of the system in its growth from the installed position to the operating
position. This displacement range is used for the calculation of the system’s expansion
stresses.

Run the static analysis

1. To proceed with the analysis, click Analyze, or Analysis load cases in the Load
Case Editor dialog box.

The software performs analysis for the piping system and the basic load cases.
When complete, the Static Output Processor displays.

You can stop the analysis at any time by clicking Cancel.

CAESAR II analyzes the basic loads (hanger design, operating, and installed). The
displacement results of cases 3 and 4 are used with the element stiffness matrices to
calculate the forces, moments, and stresses throughout the system. The difference between
the two sets of displacements is used to establish the displacement range of the piping
system as defined in L6. This new displacement set is similarly used to calculate forces,
moments, and stresses.

All the results are automatically into the Tutor._p statics output file. The contents of a ._p
file can only be examined through the Static Output Processor.

If you want to review analysis results at a later time, you do not need to rerun the static
analysis . Click Output > Reports > Static from the ribbon on the main window to
display the output.

Review the graphical analysis results

The Static Output Processor dialog box displays after static analysis or by later clicking
Output > Reports > Static from the main CAESAR II window.

With the first run of static analysis, you are typically verifying that the piping model is
responding as expected. Checking deflections and restraint loads in the operating and
installed cases should quickly uncover any major problems with the system layout or input. If
the output verifies the model, the results can be used to collect pipe stresses, support and

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equipment loads, and any other useful data found in the output. This information is useful in
documenting a good piping design or troubleshooting an inadequate one. If there are unusual
results, you will then reexamine the input.

1. Selecting the (OPE) load case, and then click 3D Plot .

A view of the of piping system model displays.

You can use commands on the Plot Tools Toolbar to control display options,
such as supports, displacements, and node numbers.

2. Click Deflected Shape or Show > Displacement > Deflected Shape. The plot
shows the centerline plot along with a normalized deflected shape of the system in the
operating condition.

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3. Change to the sustained load case on the Load Case toolbar.

4. Click Overstress or Show > Stress > Overstress.

A dialog displays verifying that there are no over-stressed points in the system.

5. Click Stress Colors by Value or Show > Stress > Stress > Code to display the
code-defined stresses throughout the system.

The stress symbols appear on the screen and locate the highest stress points in the
system.

6. Click Max Stress or Show > Stress > Maximum to list the stress values on the plot.

The maximum stress value and the node number display.

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7. Press ENTER to display the stresses one at a time starting with the highest.

8. Click Show Element Viewer Grid .

The Element Viewer displays a table of stresses, displacements, and restraints for
each load case.

9. Return to the Static Output Processor by clicking Window > 1 <file name>.

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Review the static output reports

1. For a quick look at the selected hanger data in the Static Output Processor, click
Hanger Table with Text from the General Computed Results column in the main
output processor. Then, click View Reports .

The software reports the Anvil Fig. B‑268 Size 10 spring selected at node 28.
This selection is based on the values found in the first two analyses. Both analyses
provide no load case reports in the output processor.

The expected hot load for the proposed support at node 28 (1209 lb.).

The thermal growth of node 28 (0.750 in.).

2. Return to the Static Output Processor, and select only the operating load case (OPE)
Displacements and Restraint Summary by holding down the Ctrl key.

The restraint loads at nodes 5 and 40 are compared to the pump and vessel load limits.
Note the different output tabs at the bottom of the screen.

3. Return to the Static Output Processor, and select the sustained case (SUS) to
examine the installed condition of the piping system.

Turn off 3 and turn on 4. Both the operating and sustained cases can be reviewed
together by having both 3 and 4 highlighted at the same time.

4. Return to the Static Output Processor, and highlight the sustained and expansion
cases (4 and 5) and stresses.

Each stress report begins with a summary stating that the code stresses are below their
allowable stress. In the table that follows the summary, the stresses display for each
node in the system. These nodes are listed in pairs with their associated element. The
last column lists the ratio of actual stress to allowable stress in terms of percentage.

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These results can be sent to the printer or to a file rather then sent to the screen. Before
creating the report, a title line for the hardcopy can be generated through Options-Title
Lines on the Output Menu.

5. Type the following two lines for the report header:

CAESAR II TUTORIAL

BOTTOMS PUMP TO STEAM STRIPPER

6. To send a specific output to the printer, click File > Print.

Use the output wizard to create a book of reports in a specific order and then send them
to an output device. Click More>> in the Static Output Processor to access the
wizard. Start the report with the hanger table by selecting it and clicking [Add].

7. Select the operating and sustained load cases and displacements and restraint
summary reports.

8. Click Add again.

9. Add the sustained and expansion stress reports by having only SUS and OPE load
cases and Stresses highlighted.

10. Click Add again.

This completes a typical output report after reviewing the reports order.

11. Select the output device, and then click Generate TOC, if needed.

12. Click Finish.

A tabbed window with all reports displays.

Static Analysis Output Listing

Analysis produces the following reports.

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Hanger report

The output listed in the example includes significant output only.

Notes, which discuss the results, are included with each report.

The following reports are included in this output:

Complete Hanger Report

Operating Case Displacement Report

Installed (Sustained) Case Displacement Report

Operating & Installed Restraint Summary

Sustained Stress Summary and Stress Report

Expansion Stress Summary and Stress Report. (Stresses in the operating

condition are not used in B31.3 analyses)

The hot load of 1209 lbf. was calculated in the initial weight run (load case 1) with a rigid Y
restraint installed at node 28. The load on the restraint was 1209 lbf.

A 1209 lbf. +Y load replaced the rigid Y restraint at 28 and then an operating case was
analyzed (load case 2). Node 28 moved 0.750 in. in the +Y direction in this analysis.

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CAESAR II selected an appropriate mid-range spring from the Anvil hanger table. The size 10
spring has the hot load of 1209 lbf. in its working range. This mid-range spring (short range
springs were excluded) has a spring rate of 260 lbf./in. Assuming that node 28 moves 0.750
inches between the cold to hot position, this increases the spring load by (.750)(260) or 195
lbf. The cold load on the size 10 spring is 1222+195 or 1404 lbf. This cold load is also within
the working range of the size 10 spring.

Displacements reports

The deflections of nodes 5 and 40 were entered as input. Node 28 again moves up 0.750 in.
in the Y direction with the spring installed.

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Look at the zero position of nodes 5 and 40. When the imposed displacements are not
included in the analysis, the node is fixed with zero movement in each of the defined
directions.

Restraint summary

The restraint report lists the piping forces and moments on the restraint. It does not list the
restraint loads on the piping. The loads at node 5 are the nozzle loads and can be used

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without sign change to check the API 610 allowable loads. Loads for node 40 can be used to
check the vessel stresses due to the nozzle loads.

The loads at 28 show the operating load and the actual installation load (with contents) for the
selected spring. The spring carries the designed load of 1209 pounds in the operation
condition.

The +Y restraint at node 35 shows it is nonlinear nature. In the cold condition, the restraint is
active. As the piping moves to the hot position, it disengages from the support. Refer back to
the displacement reports to confirm that the Y displacement is 0.0 in the installed (sustained)
condition and +Y in the operating condition.

The summary shows that the sustained stresses throughout the system are below their
allowable values. The sustained stress closest to its allowable limit is at the vessel node 40.

Stress reports

The summary shows that the expansion stresses throughout the system are below their
allowable values. The expansion stress closest to its allowable limit occurs along the header
at the node 10 tee.

For the stress detail report, note the application of the tee and bend stress intensification
factors. The tee at 25 has SIFs other than 1.00 for all three listings: 25 to 28, 20 to 25, and 25
to 620. Bend SIFs are applied only on the bend side of the node compare node 28 on 25-28
and 28-29. No stresses are listed for rigid elements as no valid moment of inertia is provided
for these elements.

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Conclusions
The review of piping stresses shows that the piping has adequate wall thickness and support
to keep within the sustained allowable stress, as well as enough flexibility to remain below the
expansion allowable stress limit. A quick review of the system displacements does not reveal
any interference problems from pipe expansion.

Equipment loads

Equipment loads must still be checked to ensure a safe and effective design. The pump loads
at node 5 may be compared to the API (American Petroleum Institute) Standard 610 (Seventh
Edition, February 1989), Centrifugal Pumps for General Refinery Service. The nozzle loads,
too, can be compared to the allowed maximum limits. The nozzle loads can be translated into
local stresses using Welding Research Council Bulletins 107 or 297 - Local Stresses in
Cylindrical Shells Due to External Loadings on Nozzles (WRC 107) or it's Supplement (WRC

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297). These local stresses can then be compared to allowable stress values established in
ASME Section VIII Division 2 Appendix 4, Mandatory Design Based on Stress Analysis.

Because the loads on these boundary conditions are related to the piping system layout, the
piping system cannot be properly approved until these load limits are also verified. These
verifications are performed in Tutorial B.

Archiving

Final reports should now be made to document this design. The input listing can be generated
from Classic Piping Input or from the Static Output Processor. You should include the
current status of the software’s default settings in this input echo and a hard-copy of a few
input plots. Structural and stress results from the Static Output Processor substantiate the
current design.

Archive the files Tutor-A.C2 and Caesar.cfg to preserve a copy of the CAESAR II input, load
case definition, output, and software default settings. Often upon release of a new version of
CAESAR II, archived files must be converted to the new version and subsequently re-
analyzed. This is primarily due to changes within CAESAR II as new features and codes are
added. To avoid this, keep the old version of the software available, and use newest version
for new analyses.

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Tutorial B - Check equipment and redesign a piping

system
This tutorial guides you through equipment checks on the pump and the redesign of the
system created in Tutorial A - Create a typical piping system.

1. Review piping system loads on the pump

2. Evaluate pump discharge nozzle loads

3. Review the model

4. Incorporate flexibilities at the vessel and nozzle intersection

5. Run a new static analysis for WRC 297 loads

6. Review static output reports for the new analysis

7. Re-evaluate pump discharge nozzle loads

8. Redesign the piping system

9. Rerun the static analysis

10. Conclusions

Review piping system loads on the pump

Collecting pump and load information is the first step in reviewing the pump loads. API 610
(10th Edition) examines pump loads at two levels:

Individual nozzle loads

Combined nozzle loads on the pump housing

The suction and discharge nozzles have a set of allowable load limits based on nozzle
orientation and nozzle size. The software checks the individual X, Y, and Z components, the
resultant forces, and the moments. Additionally, to assure maintenance of proper pump/motor
alignment, the software resolves all loads on the pump about a base point and compares
these loads to their allowable values.

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An API-610 pump analysis using Equipment Analysis requires the nozzle suction and
discharge sizes, positions, orientations, and loads. The processor provides the load limits. For
this tutorial, the software has already calculated the discharge nozzle loads. Therefore, the
software only checks the discharge nozzle and does not evaluate the suction limits or the
resolution to the base point.

For an analysis of a production system, you typically want both suction and
discharge loads.

Even though all loads are not known, you will provide the entire description of the pump for
Equipment Analysis. The following graphic illustrates the orientation of this pump with its
end suction nozzle and top discharge nozzle. Both nozzles are dimensioned back to the base
point, which is the intersection of the shaft axis and the support line for the pump. The drive
shaft centerline is along the local X-axis of the pump.

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Refer to the static analysis output from Tutorial A to get the discharge nozzle loads. Because
the discharge nozzle served as a boundary condition for this analysis, the restraint reports list
the nozzle loads. The forces and moments on the restraint at node 5 represent the piping
loads acting on the discharge nozzle. The operating loads and installation loads must both fall
below the defined limits. Examination of the restraint summary for the operating and
sustained (installed) cases reveals that the operating loads are the controlling case to use for
the discharge nozzle analysis.

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Evaluate pump discharge nozzle loads

Create a copy of your Tutorial A file to use for Tutorial B

1. Open CAESAR II from the Windows Start menu.

The CAESAR II main window displays.

2. In the main window ribbon, click Home > Open .

3. In the Open dialog box, navigate to the file from Tutorial A, C:\ProgramData\Intergraph
CAS\CAESAR II\<version number>\Examples\Tutor-A.c2.

4. Make a copy of Tutor-A and rename it Tutor-B.

5. Select Tutor-B.C2, and click Open.

Perform analysis on the pump using the discharge loads from the piping analysis

1. In the main window ribbon, click Analysis > Components/Equipment > Equipment
Analysis .

The Equipment Analysis dialog box displays.

2. Select API-610 in the Equipment pane on the left, and then click Add .

Pump1, with a default Suction nozzle, Discharge nozzle, and Load Case
Sets, displays in the Equipment pane.

3. Select Pump1 in the Equipment pane, and specify the following properties on the
Pump Input tab:

Equipment Name: Bottoms Pump

Description - Tutorial B. Check discharge nozzle.

Allowable Load Multiplier: 1.00

Centerline Direction Cosine X: 1.00

4. Select Suction in the Equipment pane, and specify the following properties on the
Nozzle Input tab:

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Orientation: End

Nominal Diameter: 10 in. (250 mm)

Location from Pump Center, DX (in.): 15.00

CAESAR II Node Number: 105

For this tutorial, the node number is arbitrary and does not exist in the
model. In a production analysis, the node number identifies a node containing
suction nozzle loads from the static analysis.

CAESAR II Output File - C:\ProgramData\Intergraph CAS\CAESAR

II\11.00\Examples\Tutor-B

5. Select Discharge in the Equipment pane, and specify the following properties on the
Nozzle Input tab:

Orientation: Top

Nominal Diameter: 8 in. (200 mm)

Location from Pump Center, DY (in.): 20.00

Location from Pump Center, DZ (in.): 12.00

CAESAR II Node Number: 5

This node number corresponds with the first node in the model, which
defines the discharge nozzle boundary condition in the model.

CAESAR II Output File: C:\ProgramData\Intergraph CAS\CAESAR

II\11.00\Examples\Tutor-B

6. Select Load Case Sets in the Equipment pane.

7. For the Load Cases: Bottoms Pump - Discharge grid at the top of the Load Case
Sets tab, click Add Case , and then select Import Load Cases.

The Select Load Cases dialog box displays the load cases from the CAESAR II output
file.

8. Select the OPE and SUS load cases, and click Accept.

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The load cases display in the Load Cases: Bottoms Pump - Discharge grid.

9. For the Load Cases: Bottoms Pump - Suction grid at the top of the Load Case Sets
tab, click Add Case > Add Custom.

A load case numbered 1u displays.

Because the suction nozzle has no loads for this model, leave the force and
moment values at 0.

10. Create two load case sets:

Select the suction load case and the OPE discharge load case. For the Load
Case Sets grid at the bottom of the Load Case Sets tab, click Create a Set from
Selected Load Cases .

Select the suction load case and the SUS discharge load case. Click Create a Set
from Selected Load Cases .

Two load case sets display.

11. Click Save , and name the file Tutor-B Pump.

The software creates a .C2eDB file.

12. Click Analyze .

As the analysis runs, the software places messages in the Event Log. A report displays
on the Output tab when analysis completes.

13. On the Output tab, click Next Page to advance to new pages.

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The report displays analysis results on the discharge nozzle for the OPE and SUS load
cases.

14. Click Save .

15. Click Print to print the report, or click Export to save the report in Excel, Word, or
PDF format.

Page 3 of the report shows that the analysis exceeds API Table 5 limits for the operating
load case.

When the nozzle load components are greater than the Table 5 values but less than
two times the Table 5 values, the pump might still pass (when permitted by purchaser
specifications) if other checks are within their allowable values. However, this evaluation
cannot be used because loading on the suction nozzle is unknown.

Piping loads on the pump discharge nozzle exceed API 610 allowable stresses.

Review the model

The operating moments (X, Y, and Z) on the pump nozzle are greater than the API 610
allowable limits. Because of this, you must modify the piping system to reduce these loads.
Return to the static analysis of Tutorial A to determine the causes of these large loads. You
can then make the needed changes to the piping system.

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In the Tutorial A static results, compare the operating loads on the pump to the installed loads
on the pump. If they are vastly different, the thermal effects cause the overload. If they are
similar, the sustained effects cause the high loads.

In this case, only the operating loads are high. Therefore, the piping system has a thermal
expansion problem. For a given amount of thermal growth, you can reduce the thermal forces
and moments by adding flexibility to the system. Because F = KX, you can reduce the thermal
growth between the end point forces or moments by reducing K.

If the system was overloading the pump due to sustained effects, the system
pressure or dead weight would be causing the problem. Systems with pressure problems
usually include untied expansion joints. Dead weight problems can be traced back to
improper system support. Typically, this is either spring pre-loads or support locations.

In the following figure, look at the deflected shapes displacement plot of the operating load
case to examine the source of the high moments. Most engineers and analysts find it easier
to understand system response to loads in terms of system displacements rather than internal
forces and moments. The displacement plot can be used to identify pipe runs that generate
the thermal strain and pipe runs that turn the thermal strain into large forces and moments on
the pump.

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The plot shows that the large moment about the Z-axis at the pump is caused by the thermal
growth of B working against the stiffness of legs A and C. The large moment about the X-axis
is due to the thermal growth of A working against the stiffness of legs B and C. The thermal
growth of the steam stripper vessel connection (at the left end of A and node 40 in the piping
system model) may also contribute to these high loads.

How can excessive loads at the pump discharge nozzle be reduced? How can additional
flexibility be added to the system so that these loads drop? The possible solutions are:

Incorporate flexibilities at the vessel/nozzle intersection.

Redesign the piping system to reduce stiffness by adding an expansion loop or an

expansion joint to the piping.

Incorporate flexibilities at the vessel and nozzle

intersection
Before any potentially costly piping system modifications are made, you will analyze the
model a second time to incorporate WRC 297 nozzle flexibilities. A more thorough and
accurate model of the system might show that redesign is not required. To assist in this model
update, CAESAR II calculates and inserts these flexibilities into the system. The pump loads
caused by expansion decrease if the thermal growth of the three pipe legs A, B, and C deflect
the vessel nozzle. Welding Research Council (WRC) Bulletin 297, Local Stresses in
Cylindrical Shells Due to External Loadings on Nozzles (Supplement to WRC Bulletin No.
107) defines nozzle flexibilities. WRC 297 supplies curves by which the outer diameters and
thicknesses of the vessel and nozzle define local nozzle flexibilities. These curves are limited
to specific ratios of nozzle and vessel terms, such as the following:

d/D < 0.5

d/t > 20

20 < D/T < 2500

d/T > 5

where:

d = nozzle OD (8.625 in.)

t = nozzle thickness (0.322 in.)

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D = vessel OD (60 in.)

T = vessel thickness (3/16 in wall thickness + 1/4 in. reinforcing pad = 7/16 in.)

Because the vessel is vertical and the nozzle is in the Z direction, the software defines
flexibilities at node 40 for translation along the Z-axis and rotation about the X- and Y-axes.
The other three degrees-of-freedom (the three local shear terms) remain rigid because the
nozzle was modeled as a rigid connection with its thermal deflections.

1. In the main window ribbon, click Home > Input > Piping Input with Tutor-B as the
current model file.

The Classic Piping Input dialog box and a graphic view display.

2. Click File > Save As, and change the model file name to Tutor-B2.

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3. Click Next Element repeatedly to advance through the model, or double click the
graphic view at the end of the horizontal run to display element 35-40.

4. Click the Displacements box.

The Displacements tab of the auxiliary panel displays.

5. Change the value of Node 1 from 40 to 6000. Do not change the displacement values.

Node 6000 represents the steam stripper vessel. Because the vessel has
thermal growth, the thermal displacements previously assigned to node 40 are
reassigned to the new vessel node 6000. Do not define a piping element between
nodes 40 and 6000.

6. Double-click the Nozzle Flex box.

The Nozzles tab displays on the right.

7. Specify the following properties on the Nozzles tab:

Nozzle Type: WRC 297

Nozzle Node: 40

Vessel Node (optional): 6000

Direction Cosines: VY: 1

A value of 1 for the Y-direction vector specifies a vertical vessel.

Nozzle Details:

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Outer Diameter: 8.625

Wall Thickness: 0.322

Distance to Stiffener or Head: 48.000

Distance to Opposite Stiffener: 72.000

Vessel Details:

Outer Diameter: 60.000

Wall Thickness: 0.250

Pad Thickness: 0.188

With the addition of these properties, the software applies the calculated nozzle
flexibilities between nodes 40 and 6000.

For WRC 297, the nozzle and vessel orientation defines the local coordinate
system. With the nozzle in the Z-direction and the vessel in the Y-direction, the
new axial stiffness is in the global Z-direction (the nozzle centerline), longitudinal
bending is about the global X-axis (bending into the vessel centerline or long axis),
and circumferential bending is about the global Y-axis (about the vessel
centerline).

Because WRC 297 flexibilities are sensitive to the proximity of stiffeners to the
nozzle, the software specifies the vessel dimensions. A tray in the vessel is closest
to the nozzle and 4 feet above the nozzle. On the other side of the nozzle, the
bottom head tangent and skirt connection is 6 feet below.

8. Click Save to save definition of the WRC 297 vessel nozzle.

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Run a new static analysis for WRC 297 loads

With the nozzle specification and the node number change for deflections at the vessel
nozzle, the piping system model is ready for a new analysis.

Check for errors

1. Click Start Run , or select File > Error Check to start the error checker.

The Errors and Warnings report displays.

The error checker produces two notes regarding the hanger sizing. Additionally, if the
vessel node number is not included on any piping element, the software displays a
warning regarding the specification of a vessel node number in the WRC 297 input. This
is acceptable because the displacements of the vessel node (node 6000) are defined.

The report lists the flexibilities extracted from WRC 297:

Axial stiffness of 319, 226 lb./in.

Longitudinal bending stiffness of 291,036 in.lb./deg.

Circumferential bending stiffness of 58,665 in.lb./deg.

These values are much less than the magnitude of the default rigid stiffness, which
is 10E12.

You can now perform a second static analysis on the model.

Reanalyze the model

1. Click Batch Run to run the static analysis.

The software performs a new analysis for the piping system and load cases.
When complete, the Static Output Processor displays.

2. Select the following options:

For Load Cases Analyzed, SHIFT-click to select the OPE, SUS, and EXP load
cases

For Standard Reports, CTRL-click to select Displacements, Restraint

Summary, and Stresses.

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For General Computed Results, select Hanger Table W/Text

These options simplify report creation, but create the following extra reports that
have no meaning: EXP + Displacements, EXP + Restraint Summary, and OPE + Stresses.

1. For Output Viewer Wizard, click Add, and then click Finish.

After processing completes, a tabbed window with all the reports displays.

Review static output reports for the new analysis

Because the flexibility at the vessel nozzle is the only change to the model, you do not need
to perform a thorough review of the results.

Check the sustained and expansion stresses to confirm that they are still below their allowable
limits

The highest sustained (SUS) stress is 1282 psi. This is below the allowable limit.

Similarly, the highest expansion (EXP) stress is 14,103 psi (not shown). This is also below the
allowable limit.

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Check the hanger selection

The software selected a lighter size 9 spring for installation at node 28 for a 904 lb. hot load.
For the original analysis, the software selected a size 10 spring for a 1209 lb. hot load. The
weight of the piping system did not change, but the new analysis has a reduced longitudinal
bending stiffness at the nozzle.

Check the loads at each restraint

Review the Restraint Summary, which is too large to show here.

For the pump discharge nozzle at node 5:

The pump discharge nozzle loads reveal the impact of the change in flexibility at node
40.

The operating moment about the Z-axis shows the greatest change, dropping to 747
ft.lb. from 5905 ft.lb.

The shear force in the X-direction has been reduced by 50%.

The axial force in the Y-direction has risen from 1556 lb. to 1809 lb. This higher pump
load is tied directly to the lighter hanger selection, which was also affected by the WRC
297 nozzle flexibilities.

For the spring support at node 28:

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In the operating position, the spring now carries 904 lb instead of 1209 lb. This reduction
in the spring load returns as an additional 300 lb. load on the pump nozzle. With the
spring installed directly above the pump nozzle, increasing the load carried by the spring
can reduce the load on the nozzle. For additional analyses, the hanger sizing procedure
can be adjusted so that the hanger carries more load and the pump carries less load.

For the +Y support at node 35:

The +Y support reveals why the hanger load has changed so much. In the first analysis,
the support at node 35 was not active in the operating case. The pipe rested on the
support in its installed position, but lifted off the support as it went into operation. The
hanger sizing algorithm re-adjusted the spring load so that the spring carries its portion
of the system, with the system no longer resting at 35. In this second analysis, the
restraint at 35 remains active in the operating position, therefore the hanger at 28 does
not carry any additional load from 35. The added longitudinal bending flexibility at node
40 allows the pipe to rest at node 35.

For the vessel nozzle at support 40:

The support definition at node 40 shows the changes inherent in the WRC 297 nozzle
flexibility calculations. Flexibilities are added in the axial and bending directions (Z, RX,
and RY), while the shear terms (X, Y, and RZ) remain rigid. This added flexibility greatly
reduces the bending moments about the X- and Y-axes at node 40.

The reduced loads result from modeling refinements, not design modifications. If the vessel
nozzle connection meets the requirements of WRC 297, you can gain much from nozzle
flexibility.

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Show the displaced position of the piping system in its operating condition

The imposed thermal growth of the nozzle (in the original analysis) was removed from node
40 and redefined at node 6000. When you compare displacements at node 6000 and node
40, you can see the impact of the nozzle flexibilities. Circumferential bending flexibility (RY)
and longitudinal bending flexibility (RX) play a large role in the weight distribution of the
system.

You now must reanalyze the pump discharge nozzle loads to see if they meet the allowable
limits of API 610.

Re-evaluate pump discharge nozzle loads

You can now run another API-610 analysis using the updated discharge loads.

1. Close the Static Output Processor dialog box.

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2. In the main window ribbon, click Analysis > Components/Equipment > Equipment
Analysis .

The Equipment Analysis dialog box displays, containing values from the initial
analysis.

3. Select Load Case Sets in the Equipment pane.

4. For the Load Cases: Bottoms Pump - Discharge grid at the top of the Load Case
Sets tab, click Refresh Linked Cases .

The force and moment values for each load case update with values from the new static
analysis.

5. Click Analyze .

As the analysis runs, the software places messages in the Event Log. A report displays
on the Output tab when analysis completes.

6. On the Output tab, click Next Page to advance to new pages.

The report displays analysis results on the discharge nozzle for the OPE and SUS load
cases.

7. Click Save .

Page 3 of the report shows that while results are improved, the analysis still exceeds API
Table 5 limits for the operating load case.

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The report shows that the Y-moment on the discharge nozzle is well below the limit. The X-
moment remains more than twice the allowable load. The Z-moment also exceeds the
allowable.

Exceeding twice the allowable load would be fine if Condition F.1.2.b is satisfied, but it is not,
as shown on page 5 of the report.

The sum of the ratios is 2.82, which does not meet condition F.1.2.b, which states that the
combined force/moment load ratios must be less than 2.0. The pump loads are still too high.

The spring support in the model might prove the pump loads can be brought within
their allowable values. As discussed in Review static output reports for the new analysis, the
spring at node 28 directly controls the vertical load on the discharge nozzle. This spring pre-
load could be ideally set so that when the pump is in operation, there is no pump load in the

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Y-direction. For the current analysis, the hanger carries 904 lb. in the operating position while
the pump carries 1809 lb. If the spring load carried 2713 lb., the load on the pump would be
zero (0) in Y.

For a quick check, you can manually set the Y-load to 0, and then reanalyze the pump in
Equipment Analysis. The results show Condition F.1.2.b reduced to 2.33, which remains
above the allowable load limits.

Pump loads are still above allowables, and a redesign of the system is needed.

Redesign the piping system

As discussed in Review the model, the large X-moment at the pump discharge nozzle (node
5) is caused by the thermal expansion of leg A (from node 35 to node 40) working against the
stiffness of legs B and C. If the thermal strain of leg A is fixed, only the system stiffness can
be changed to reduce the operating load at node 5. You can reduce this stiffness by adding
an expansion loop or an expansion joint. For this tutorial, you will add an expansion loop.

The best location for an expansion loop is determined by the orientation of leg A, which
creates the excessive thermal strain. The added piping to generate the expansion loop lies
perpendicular to leg A. For this system, pipe can be added in either the X- or Y-direction. This

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added pipe effectively increases the cantilever length which is displaced by leg A. By
increasing the cantilever length, the stiffness is reduced and loads drop.

There are several conditions which set the loop size:

Available support location

Maximum distance between supports

Cost of pipe

Available space

For this tutorial, you will add an eight-foot by eight-foot loop of pipe and an additional support
on leg A in the X-direction. For systems that are not analyzed, the recommended maximum
spacing between supports for 8-inch water-filled pipe is 19 feet (see ASME B31.1 121.5 or
MSS SP-69). The 8-foot loop run lengthens the 30 - 35 pipe from 12 feet to 20 feet, which is
close to the recommended spacing.

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Modify existing elements in the model

When testing layout modifications, you should save the existing model as a new file
and leave the original model intact. If the proposed changes do not produce the required
results, the original model is still available for the next attempt. You then do not have to delete
the proposed changes from the model.

1. Return to the main window ribbon, and click Home > Input > Piping Input with
Tutor-B2 as the current model file.

The Classic Piping Input dialog box and a graphic view display.

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2. Click File > Save As, and give the model file a new name of Tutor-B3.

3. Click Next Element repeatedly to advance through the model to display element 30-
35.

You can also click on element 30-35 or use Find Node to go directly to the
element.

4. In the DX box, type -20- to change the element length from 12 ft. to 20 ft. Press TAB.

5. Click the Restraints box to display the Restraints tab on the right.

6. For the +Y restraint, change Node from 35 (the node at the end of the elbow) to 33 (the
node at the beginning of the elbow).

The recommended maximum spacing, a conservative guideline, of 19 feet for an

8-inch pipe limits sag between supports to 0.1 in. With the restraint at node 35, the
distance to the node 28 hanger is 21 ft. Moving the restraint to node 33 decreases
the distance to 20 ft., closer to the recommended maximum.

The maximum distance between supports as specified in ASME B31.1 and MSS
SP-69 ensures a very low sustained stress in the line. Because CAESAR II
calculates the sustained stresses, the output confirms that much greater distances
than the recommended maximum between supports are safe.

7. Click Break .

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You can also right-click the element and select Element > Break Element.

The Break at Element dialog box displays.

8. Break element 30 - 35 by adding node 32 at the 10 ft. (10-) midpoint, and then click OK.

9. Click Next Element twice to advance to element 35-40.

10. Click Break , and add node 135 at 8 ft. (8-) from node 35.

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Add a new elbow at node 135 to begin creating the loop

1. Double-click the Bend check box to display the Bends tab on the right.

The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node
133 at the elbow near point (Angle 2 of 0.000), and node 134 at the midpoint (Angle 1
of M). Node 135 moves to the elbow far point.

The elbow is part of the horizontal pipe run, but does not display until you
create the horizontal pipe run.

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Insert an 8-foot element after the elbow

1. Click Insert Element , select After to place this new element after element 35 - 135,
and then click OK.

The From node changes to 135.

2. In the To node box, type 235.

3. In the DX box, type 8- (for 8 ft.), and then press TAB.

The software creates the last element of the loop. The last element of the pipe remains
in its original location.

Add an elbow and adjust the From node for the final element

1. Double-click the Bend check box to add the bend at node 235.

The software creates a long radius elbow (1-1/2 times the nominal pipe diameter), node
233 at the elbow near point (Angle 2 of 0.000), and node 234 at the midpoint (Angle 1
of M). Node 235 moves to the elbow far point.

Again, the elbow is part of the horizontal pipe run, but does not display until you
create the horizontal pipe run.

2. Click Next Element to advance to element 135 - 40.

3. In the From node box, type the value of the new node, 235, and then press TAB.

The software attaches the new loop to the last element of the pipe.

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Add a support to the new element 135 - 235

ASME B31.1 and MSS SP-69 provide limits to spacing between supports when bends are
included, such as for this expansion loop. The maximum support spacing for 8-inch carbon
steel water line is 19 ft. The maximum run of pipe is 3/4 of the straight run limit. For this model
the limit is about 15 feet. There are over 26 feet of pipe between 35 and 40, so a new support
is required.

1. Click Previous Element to go back to element 135 - 235.

2. Click Model > Insert Restraint , or right-click the element and select Restraint >
Insert Restraint.

3. Insert the restraint by adding node 140 at 5 ft. (5-) from node 135. In Copy Restraint
from Node, use the same +Y support as used at node 33 to create a new support with
the same properties at node 140.

The software breaks the element and inserts the new restraint.

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Adjust the sizing of the hanger at node 28

A large vertical load remains on the pump nozzle after the hanger at node 28 was sized by
the software. The spring selected in Tutorial A from the 1 - ANVIL hanger table can carry
more of the dead weight of the pipe and valving. You will adjust the sizing algorithm, so that
the pump nozzle carries no load when the software calculates the load to be carried by the
larger spring.

1. Click Previous Element to go back to element 25 - 30. Click Hangers to display the
Hangers tab on the right.

2. In the Free Restraint at Node box, type 5.

3. In the Free Code list, select 1-Y.

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The software disconnects the vertical Y restraint at node 5 while it calculates the dead
weight load carried by the proposed spring at 28, allowing the spring to carry the full
vertical load.

4. To save the model, click Save or File > Save.

5. As a final check, click Distance . Select Between Element Nodes, type 5 (the first
element) and 40 (the last element) in the boxes, and then click Calculate. In Results,
the length should be 26' 8 3/8", the same distance you measured in Tutorial A.

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Your model redesign is complete!

Rerun the static analysis

1. In the Classic Piping Input dialog box, click Start Run to run the Error Checker.

Error checking should complete without any warning or error messages. The model is
ready for static analysis.

If any errors do occur, carefully read the messages and return to Classic
Piping Input to correct them.

2. Click Batch Run to run the static analysis.

The software performs analysis for the piping system and the basic load cases.
When complete, the Static Output Processor displays.

The model uses the load cases created for the original model in Tutorial A. For
more information, see Check the static load cases.

Review the graphical analysis results

1. Selecting the (OPE) load case, and then click 3D Plot .

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A view of the piping system model displays.

2. Click Deflected Shape .

The graphics show the model and a normalized deflected shape of the system in the
operating condition.

3. To return to the Static Output Processor, close the graphics window.

Generate the static output reports

1. Create a set of reports by selecting:

For Load Cases Analyzed, SHIFT-click to select the OPE, SUS, and EXP load
cases

For Standard Reports, CTRL-click to select Displacements, Restraint

Summary, and Stresses.

For General Computed Results, select Hanger Table W/Text

2. For Output Viewer Wizard, click Add, and then click Finish.

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The reports display in a tabbed window.

Review the stress reports

Check the sustained stresses (shown below) and expansion stresses (not shown) to confirm
that they remain below their allowable limits. The highest sustained are 2017 psi and the
highest expansion stresses are 5419 psi, below the allowable stress limits. The sustained
stresses increased a small amount because of the longer spans between supports while the
expansion stresses show a significant reduction. The added system flexibility caused this
reduction in expansion stress. That is a good indication that the nozzle loads have dropped as
well.

Review the hanger report

Examine the impact of the hanger modification on the pump nozzle loads at node 5.

The software selected a heavier spring (size 12) for installation at node 28. In the original
Tutorial A analysis, a size 10 spring was selected. The spring now carries 2202 pounds in its
hot position. This greater load is the result of the modification to the spring hanger selection
criteria where the pump is disconnected in the Y direction when the software calculates the

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spring’s hot load. The added load-carrying capability of the spring reduces the vertical load on
the pump nozzle.

Review the restraint summary

The operating and sustained (installed) restraint summary show the impact of this model
modification on the pump nozzle loads at node 5.

The pump discharge nozzle loads at node 5 look much better, showing the impact of the
change in flexibility at node 40. The loop adds flexibility in the Z-direction. The Z-force on the
pump falls from 747 pounds to 235 pounds. The large operating moment about the X-axis and
the target of this redesign drops from almost 10,000 pounds to 2,755 pounds.

Another interesting effect of this added flexibility is the increase in the Z-moment from -300
foot-pounds to +1519 foot-pounds. The pump load in the Y-direction exhibits the adjustment to
the hanger selection. The hot load on the pump is -206 pounds and the cold load on the pump
is +337 pounds. If necessary, the hanger load could be adjusted to bring the pump installation
load to zero or the pump operating load to zero. The spring support at node 28 now shows a
hot load of 2,202 pounds and a cold load of 2,540 pounds.

By releasing the anchor in the initial weight analysis, the spring carries the riser load. This
load was only 904 pounds in the original analysis. The extra flexibility also changed the
support load at node 33. Originally, the support load dropped as the pipe became hot. Now,
the load increases as the pipe heats up. The vessel nozzle loads at node 40 show a similar
pattern of change as the pump nozzle. Most loads drop, but there is one moment (in this case
it is X) that increases.

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Review nozzle loads

Confirm that the discharge nozzle loads are below their maximum allowed values. Refresh
discharge loads in Equipment Analysis and rerun the analysis, or refer to the original
analysis to quickly locate the individual limits and compare them to the new operating loads
on node 5:

Direction API Limit Model Results

X (lb.) 1700 136

Y (lb.) 2200 -206

Z (lb.) 1400 -235

RX (ft.lb.) 5200 -2755

RY (ft.lb.) 3800 -1540

RZ (ft.lb.) 2600 1520

For this exercise, the loading on the suction side of the pump is assumed to meet
allowable loading. Two times the API allowable loading was used.

Because all six components of the discharge nozzle loads are below their limits, no additional
checks (conditions F.1.2.b. and F.1.2.c.) need to be made. The discharge nozzle is no longer
overloaded. The final pump evaluation cannot be made until the suction nozzle loads are
compared with their API 610 limits.

Conclusions
Piping stresses show that the pump discharge loads are now within their allowable limits.

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Vessel loads

While not part of this tutorial, the vessel loads from the nozzle at node 40 should also be
checked. Unlike loads on the pump, these loads cannot be compared to a fixed load limit.
Instead, these loads must be converted to local stresses on the vessel and then compared
with the limits defined by ASME Section VIII, Division 2. As a very rough guide for evaluating
local vessel stresses, you can check the code defined stress on the pipe connected to the
vessel. If those stresses are below about 6000 psi, the vessel stresses should be adequate.
Looking at the operating, sustained, and expansion stresses at node 40, the maximum stress
is less than 2500 psi. The vessel loads seem fine.

To check the stresses in detail, the Welding Research Council Bulletin 107 (WRC 107) can be
used to convert the applied forces and moments to the appropriate local stresses. CAESAR II
provides a processor to convert these loads into WRC 107 stresses and a second processor
to combine the different stress categories (general or local primary membrane stress intensity,
primary membrane plus primary bending stress intensity, and primary plus secondary stress
intensity) for comparison with their design limits.

Archiving

Final reports should now be made to document this design change. The input listing can be
generated from Classic Piping Input or from the Static Output Processor. You should
include the software's current default settings in this input echo and a hard-copy of a few input
plots. Structural and stress results from the Static Output Processor substantiate the current
design.

Archive the files Tutor-B3.C2 and Caesar.cfg to preserve a copy of the CAESAR II input, load
case definition, output, and software default settings. Often upon release of a new version of
CAESAR II, archived files must be converted to the new version and subsequently
reanalyzed. This is primarily due to changes within CAESAR II as new features and codes are
added. To avoid this, keep the old version of the software available to view existing analyses,
and use the newest version for new analyses.

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Bends
This section provides guidelines and recommended best practices for the modeling various
bend geometries in CAESAR II.

For detailed information about using the software to define bend geometry, see
"Component Information" in the CAESAR II User's Guide.

Bend Definition
A bend is defined by the element entering the bend and the element leaving the bend. The
bend curvature is always physically at the To end of the element entering the bend.

The input for the element leaving the bend must follow the element entering the bend. The
bend angle is defined by these two elements. The default bend radius is 1-1/2 times the pipe
nominal diameter (long radius), but it can be changed to any other value. When you specify a
bend, two additional intermediate nodes are automatically generated--one at the 0º location
and one 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,
adjacent to the straight element leaving the bend. The 0º point on the bend is at the weld line
of the bend, adjacent to the straight element entering the bend.

The From point on the element is located at the 0º point of the bend (and no 0º node point is
generated) if the total length of the element as specified by DX, DY, and DZ is equal to:

R tan (b / 2)

Where b is the bend angle, and R is the bend radius of curvature to the bend centerline.

Nodes defined by the Angle and Node properties 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 b
degrees at the far-point of the bend. Angles are always entered in degrees. Entering the letter
M as the angle designates the bend midpoint.

Nodes on the bend curvature cannot be placed closer together than the angle distance
specified by Minimum Angle to Adjacent Bend in the Geometry category of the Tools >

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Configure/Setup command. This includes the spacing between the nodes on the bend
curvature and the near- and far-points of the bend.

The minimum and maximum total bend angle is specified by the Minimum Allowable Bend
Angle and Maximum Allowable Bend Angle properties, also in the Geometry category of
the Tools > Configure Setup command.

Single and Double Flanged Bends or Stiffened Bends

Single- and double-flanged bend specifications affect only 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 typing a 1 or 2 to
define the Type in the bend auxiliary input. Rigid elements defined before or after the bend do
not alter the stiffness of the bend or its stress intensification factors.

When specifying single-flanged bends, it does not matter on which end of the bend you place
the flange.

If you want to include the weight of the rigid flange at the bend ends, then put rigid elements
(whose total length is the length of a flange pair) at the bend ends where the flange pairs
exist.

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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.

The flanges in the figures below are modeled only to the extent that they affect the stiffness
and the stress intensification for the bends.

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180º Return Fitting-to-Fitting 90º Bends

Separate two 90º bends by twice the bend radius. The far-point of the first bend is the same
as the near-point of the second, or following, bend. You should place nodes at the midpoint of
each bend that comprise the 180º return.

DX = 2R

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Mitered Bends
Evenly spaced mitered bends, whether closely or widely spaced, are defined by two
parameters:

The number of cuts (changes in direction)

The equivalent radius or miter spacing

For closely spaced miters, the equivalent radius is equal to the code defined as R1 for B31.3
and R for B31.1. The equation for the equivalent radius to the spacing for evenly spaced
miters is:

Req = S / [ 2 tan(q) ]

Where:

Req = equivalent miter bend radius

S = spacing of the miter cuts along

the centerline

q = code-defined half-angle
between adjacent miter cuts: q
= a / 2N

Where:

a = total bend angle

N = number of cuts

When using B31.1, an additional parameter, B (length of miter segment at crotch), is

examined for closely spaced miters. The following equation is used to compute B for evenly
spaced miters:

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B = S [ 1 - ro / Req ]

Where:

ro = outside radius of pipe cross-

section

Closely-Spaced Mitered Bend

Miter bends are closely spaced if:

S < r [1 + tan (q)]

Where:

S = miter spacing

r = average pipe cross section radius: (ri+ro)/2

q = one-half the angle between adjacent miter cuts

B31.1 has additional requirements:

B > 6 tn

q £ 22.5 deg.

B = length of the miter segment at the crotch.

tn = nominal wall thickness of pipe.

Closely spaced miters, regardless of the number of miter cuts, can be defined as a single
bend. CAESAR II always calculates the spacing from the bend radius. If you have the miter
spacing but not the bend radius, the radius must be calculated as shown in the following
example. The mitered bend shown below has four cuts through 90º and a spacing of 15.913
inches.

q = a / 2N

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= 90 / [2(4)]

= 11.25º

Req = S / [ 2 tan (q)]

= 15.913 / [2 tan (11.25º)]

= 40

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Widely-Spaced Mitered Bend

Mitered bends are widely spaced if:

S ³ r * [1 + tan (q)]

Where:

S = spacing between miter points

along the miter segment
centerline

r = average cross section radius

(ri+ro)/2

q = one-half angle between

adjacent miter cuts

B31.1 has the following additional requirement:

q £ 22.5º

In CAESAR II, you must enter widely spaced miters as individual, single-cut miters, each
having a bend radius equal to:

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R = r [1 + cot (q)] / 2

Where:

R = reduced bend radius for widely spaced miters.

During error checking, CAESAR II produces a warning message for each mitered component
that does not pass the test for a closely spaced miter.

The following components should be re-entered as a group of single cut joints.

Pipe O.D. = 10.375 in. Assuming closely spaced:

Pipe Thickness = 0.500 in.
Bend Angle = 90º
Cuts = 2
Req = 45 inches

Calculate the D coordinates to get from the tangent intersection point of the single cut miter
bend at node 10 to the single cut miter bend at node 15.

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The straight pipe section coming into and going out of the bend must be ³ Reqsin (q).

Enter widely spaced miters as individual straight pipe elements, with bends specified, having
one miter cut.

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Elbows - Different Wall Thickness

When you define the fitting thickness for the bend, CAESAR II changes the thickness only of
the curved portion of the bend element. The thickness of any preceding or following straight
pipe is unaffected.

The specified fitting thickness applies only for the current elbow and is not persisted 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.

In the following example, the elbow at node 10 has a thickness larger than the matching pipe
wall. The matching pipe has a thickness of 0.5.

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Bend Flexibility Factor

Usually, bend flexibility factors are calculated according to code requirements. However, you
can override the code calculation by typing a value for the K-factor. For example, if you type
1.500, then the bend is 1.5 times as flexible as a straight pipe of the same length.

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Restraints
This chapter provides guidelines and recommended best practices for modeling different
types of restraints in CAESAR II.

Anchors
Use the following guidelines when modeling anchors in CAESAR II:

The anchor default stiffness for translational and rotational degrees-of-freedom is

defined in the CAESAR II configuration file.

You can use connecting nodes with anchors to rigidly fix one point in the piping system
to any other point in the piping system.

The value that you define for the Stif property applies to all six anchor degrees-of-
freedom.

Do not specify displacements at an anchor. If you know the displacements of a

particular point, specify them without any additional restraints or anchors.

Accurate definition of piping boundary conditions (restraints) is considered the single

most important part of system modeling. It requires experience with piping fabrication
and erection and with CAESAR II.

The example below shows a nozzle connection modeled as an anchor, along with the
corresponding rigid anchor input on the Restraints Auxiliary Data tab in the Classic Piping
Input dialog box.

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Anchors with Displacements

Follow these guidelines to model anchors with displacements in CAESAR II:

Enter only displacements for the node.

Do not specify restraints or anchors at the node to be displaced.

For anchors with displacements, ensure that all six degrees-of-freedom at the node are
defined.

Degrees-of-freedom not defined (left blank) in any displacement vector are presumed
to be free in all load cases.

You can define up to nine different displacement vectors.

Non-zero displacements are usually part of the thermal expansion effects. They should be
added into any analysis case containing the corresponding thermal, such as W+P1+T1+D1.
We recommend load cases that do this automatically.

The translations and/or rotations for any nodal degree of freedom that has displacements
specified in any displacement vector are zero for the following load cases:

Those that do not contain a vector as part of the load case identification

Those where the specified non-zero value for load cases containing the vector is part of
the load case identification

For example, defined displacements are used if the load case is W+P1+T1+D1 (OPE), and
those displacements are held to zero if the load case is W+P1 (SUS).

After a degree-of-freedom is fixed in one displacement vector, it cannot be free in another

displacement vector at the same node.

The default value for a blank displacement box is zero.

The figure below shows an anchor with predefined displacements.

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Flexible Anchors
Use the following guidelines to model flexible anchors in CAESAR II:

Use six flexible restraints.

Refer to the following flexible nozzle examples to improve modeling methods for
intersections of this type.

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For more information about defining restraints, see "Restraints" in the CAESAR II
User's Guide.

Flexible Anchors with Predefined Displacements

To model flexible anchors with predefined displacements, use the following guidelines:

Use six flexible restraints.

Define a unique connecting node (CNode) at each of the six restraints. All six restraints
should have the same connecting node.

Specify the displacements at the connecting node.

The CNode in the following example is 1005. CNode numbers must be unique.

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Flexible Nozzle - WRC Bulletin 297

When modeling flexible nozzles, adhere to the following requirements:

Frame only one pipe element into the nozzle node.

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Do not place restraints at the nozzle node.

Do not place anchors at the nozzle node.

Do not specify displacements for the nozzle node. Refer to the displacements at flexible
nozzles below.

CAESAR II automatically performs the following functions:

Calculates nozzle flexibilities for user-defined nozzle/vessel data.

Calculates and inserts restraints to simulate nozzle flexibilities.

Calculates flexibilities for the axial translations, circumferential, and longitudinal

bending.

You must complete the error check process to view these calculated values.

CAESAR II uses the following criteria for its calculations:

Shear and torsional stiffnesses are assumed rigid.

Nozzle configurations outside of the WRC 297 curve limits are considered rigid. It is not
unusual for one stiffness value to be rigid because of curve limits and for the others to
be suitably flexible.

You can use Vessel Temperature and Material in the WRC 297 auxiliary data area to
optionally compute a reduced modulus of elasticity for the local stiffness calculations.

Example

Schematic

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WRC 297 Input

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WRC 297 Output

WRC 297 Nozzle Calculations

Flexible Nozzle with Predefined Displacements

To model flexible nozzles with predefined displacements (WRC-297), use the following
guidelines:

Define a unique vessel node in the nozzle auxiliary data area (Classic Piping Input
dialog box).

Apply the predefined displacements to the vessel node.

These displacements can be specified on any element. The displacement node does
not need to be on an element that defines it.

The CAESAR II-generated nozzle/vessel flexibilities are inserted in restraints that act between
the nozzle node and the vessel node.

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Flexible Nozzle with Complete Vessel Model

To model a flexible nozzle that includes a complete vessel, use the following guidelines:

Define a unique vessel node on the nozzle auxiliary data area.

The nozzle auxiliary data area displays when you select Nozzle Flex on the
Classic Piping Input dialog box. For more information, see "Nozzle Flex" in the
CAESAR II User's Guide.

Run a rigid element between the vessel node defined in the nozzle auxiliary data area
and the centerline of the vessel. The outside diameter of the rigid element should be
approximately equal to the outside diameter of the vessel. The weight of the rigid
element should be zero.

Model the actual vessel length using pipe elements. Model the vessel diameter and wall
thicknesses as accurately as possible

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Use an anchor to model the vessel anchorage point.

The CAESAR II-generated nozzle/vessel flexibilities are inserted between the nozzle node
and the vessel node.

Example

Schematic

Input

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Output

Double-Acting Restraints
Double-acting restraints are those that act in both directions along the line of action. The most
commonly used restraints are double-acting.

A CNode is the connecting node. If you do not enter a value in the CNode box, the restrained
node is connected using the restraint stiffness to a rigid point in space. If you do enter a value
for CNode, the restrained node is connected using the restraint stiffness to the connecting
node.

If you specify a gap, it is the amount of free movement along the positive or negative line of
action of the restraint before resistance to movement occurs. A gap is a length, so it is always
positive.

Translational Restraints

Rotational Restraints

Translational Restraints
Restraint acts along both the positive and negative directions. Friction at double-acting
restraints acts orthogonally to the line of action of the restraint.

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Rotational Restraints
The behavior of rotation restraints is similar to double-acting translational restraints. Friction is
not defined for rotational restraints.

Restrain all except Rz

Four restraints on one element containing

node 105 and remaining restraint on the next
element.

Single-Directional Restraints
The following are some important facts pertaining to single-directional restraints:

The plus or minus sign (+/-) on the single-directional restraint gives the direction of free
movement. For example, a positive Y restraint (+Y) can move freely in the positive Y-
direction and is restrained against movement in the negative Y-direction.

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Single-directional restraints can define restraint along positive, negative, or skewed

axes.

Any number of single-directional restraints can act along the same line of action. If more
than one single-directional restraint acts along the same line of action, then there are
usually two in opposite directions and are used to model unequal leg gaps.

A CNode is the connecting node. If you do not define a value for CNode, then the
restrained node is connected using the restraint stiffness to a rigid point in space. If you
enter a value for CNode, then the restrained node is connected using the restraint
stiffness to the connecting node.

You can specify friction and gaps with single-directional restraints. The gap is in the
opposite direction of the free travel.

The plus or minus sign (+/-) on the restraint

gives the direction of free movement.
Because the stiffness is omitted, the restraint
is rigid.

Guides
Use the following guidelines when modeling guides in CAESAR II:

Guides are double-acting restraints with or without a specified gap.

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You can use connecting nodes (CNodes) with guides.

You can define guides using the global system coordinates or using the applicable
options in the restraints auxiliary data area.

The restraints auxiliary data area displays when you select Restraints on the
Classic Piping Input dialog box.

A guided pipe in the horizontal or skewed direction has a single restraint, acting in the
horizontal plane, orthogonal to the axis of the pipe.

A guided vertical pipe has X- and Z-direction supports.

CAESAR II computes direction cosines for guides. The software ignores user-defined guide
direction cosines.

Guide on Horizontal Pipe with Single Directional Restraint

Node 25 is guided in Z with a gap of 2.5

inches. A single-directional restraint in the Y-
direction also exists. Both restraints are rigid.

In this example, replacing the guide

restraint with a Z restraint is equivalent.

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Guided Pipe in Both Horizontal and Vertical Directions

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Limit Stops
Use the following guidelines when working with limit stops in CAESAR II:

Limit stops are single- or double-acting restraints whose line of action is along the axis
of the pipe.

The plus or minus sign (+/-) on the single-directional restraint gives the direction of
unlimited free movement.

A limit stop and a single-directional restraint can have gaps. The gap is the distance of
permitted free movement along the restraining line of action.

A gap is a length and is always positive. The plus or minus sign (+/-) on the restraint
determines the orientation of the gap along the line of action. The gap direction is
opposite to the direction of free travel.

You can use connecting nodes (CNode) with any limit stop model.

A limit stop can be defined using the restraint type LIM.

Limit stops provide double- or single-acting support parallel to the pipe axis. Limit stops
can have gaps and friction. The positive line of action of the limit stop is defined by the
From and To node on the element.

CAESAR II computes direction cosines for orthogonal or skewed limit stops. The
software ignores user-defined limit stop direction cosines.

Directional Limit Stop with a Gap

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Two Limit Stops Acting in Opposite Directions

The stop at node 45 permits unlimited free movement in the positive X-direction and 1.0
inches of free movement in the negative X-direction before the limit stop becomes active.

The stop at node 195 permits unlimited free movement in the negative X-direction and 1.0
inches of free movement in the positive X-direction.

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Windows
Use the following guidelines when modeling windows in CAESAR II.

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, as shown in the example below.

The gap is always positive. The plus or minus sign (+/-) on the restraint determines the
direction of movement before the gap closes. If there is no plus or minus sign (+/-) on
the restraint, then the restraint is double-acting, and the gap exists on both sides of the
line of action of the restraint. If there is a plus or minus sign (+/-) on the restraint, then
the gap exists on the restrained line of action of the restraint. For example, a positive Y
(+Y) restraint is restrained against movement in the negative Y-direction. Any gap
associated with a positive Y restraint is the free movement in the negative Y-direction
before the restraint begins acting.

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Window Modeled with Four Single-Directional Restraints with Gaps

Rotational Directional Restraints with Gaps

Rotation directional restraints with gaps are considered specialty items. Usually, they used
only in sophisticated expansion joint or hinge models.

Bi-Directional Rotational Restraint With Gap

Allowable rotation of 5º in either direction about the Z-axis before resistance to rotation is
encountered.

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Hinge Assembly With Directional Rotational Restraint

The hinge assembly at node 50 can rotate relative to assembly at node 55 only in the positive
direction about the Z-axis.

Single-Directional Restraint with Predefined Displacement

Define the one-directional restraint as usual, and enter a unique node number in the CNode
box. Specify the predefined displacements for the CNode.

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Piping at node 55 rests on top of the restraint that is displaced in the Y-direction, simulated
by node 1055.

Single-Directional Restraint and Guide with Gap and

Predefined Displacement
Define the single-directional restraint and guide as usual. Enter a unique node number in the
CNode boxes for the single-directional restraint and the guide. Use the same node number
for both. Specify the predefined displacements for the CNode.

Guided piping at node 70 rests on a structural

member node 1070. The structure undergoes
a predefined displacement.

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In the example above, ignoring other loads that may be acting on the pipe, the 0.250-
inch gap will be closed in the negative X-direction, and the pipe will have a displacement of
0.50-inches in the positive X-direction.

Restraint Settlement
Use the following guidelines when modeling restraint settlement in CAESAR II:

Model restraint settlement using a single-directional restraint with predefined

displacements. The magnitude of the predefined displacement is the amount of
anticipated settlement in the negative Y-direction.

The operating load case is used to include the effect of settlement.

The settlement displacements are prescribed for the connecting node at the single
directional restraint. For more information, see Single-Directional Restraint with
Predefined Displacement.

Settlement is considered to be an EXP load with a half-cycle.

The weight of this pipe at node 95 exerts a

sufficient load on the foundation node 1095 to
cause a calculated 0.325-inch settlement.

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Skewed Double-Acting Restraint with Gap

Use the following guidelines when modeling skewed restraints in CAESAR II:

You can use direction vectors or direction cosines to define the line of action of the
restraint. If direction vectors are used, CAESAR II converts them to direction cosines.

Direction cosines can be quickly checked in the graphics processor.

Any translational axis can be used in the restraint description. The redefinition of the
axis does not affect any other restraint description for the element.

Use caution when entering skewed direction input data. A common mistake is to specify
an axial instead of transverse restraint when modeling a skewed guide. Plotted section
views of the restrained nodes are a useful check of the skewed direction specification.

The sense of the direction or cosine unit vector is unimportant. In the definition of
double-acting restraints, the direction vector and cosines are used only to define the
restraint line of action and are not concerned with a direction along that line.

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You can use a simple rule for finding perpendicular, skewed, or direction vectors. The
restraint is to be perpendicular to the pipe. If the pipe has skewed delta dimensions DX
and DZ, the perpendicular restraint directions vector is (DX, 0, -DZ).

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Skewed Single-Directional Restraint

Use the following when modeling skewed single-directional restraints in CAESAR II:

Skewed restraints can be nonlinear.

Direction vectors or direction cosines can be used to define the line of action of the
restraint. If direction vectors are used, CAESAR II converts them to direction cosines.

The direction of the cosines or the direction vector is along the positive line of action of
the positive (+) restraint. Refer to the example below

Direction cosines can be quickly checked in the graphics processor.

You can use connecting nodes (CNode) with any skewed single-directional restraint.

Restraint between Two Pipes Using CNodes

For the following two examples, make sure Connect Geometry Through CNodes is
not selected to avoid plotting and geometry errors. For more information, see "Geometry
Definitions" in the CAESAR II User's Guide.

Nonlinear or linear restraints can act between two different pipe nodes. The CNode property
effectively represents to what the other end of the restraint is attached.

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Nonlinear Restraint Between Two Pipes

Rigid Rod Hanger Between Two Pipes

Restraint between Vessel and Pipe Models

Use the following guidelines when modeling restraints that between vessel and pipe in
CAESAR II:

Use a restraint with a connecting node to link the pipe to the rigid element that extends
from the vessel shell.

You can specify any number of restraints between the restrained node and the
connecting node.

Restraints can be linear or nonlinear with gaps and/or friction.

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Restraints on a Bend at 45º

Linear and/or non-linear restraints can act at any point on the bend curvature. Points on the
bend curvature are like any other point in the piping system.

The figure below shows a bend supported vertically by a rigid rod. The rod is allowed to take
tensile loads only, so it is modeled as a single-directional restraint that can move freely in the
positive Y-direction.

If the positions of nodes 19 and 20 are unclear, see Bends.

The line of action of the rod is shifted away from node 19. A downward force at node 15
produces a positive Z-moment about node 20 in the system as modeled, but a negative Z-
moment about node 20 in real-time.

The magnitude of this moment is a function of the load and the moment arm (the amount of
the shift). If this is considered significant, then a rigid element with zero weight can be placed
between node 19 and the actual point of rod attachment. The restraint is then placed at the
actual point of rod attachment.

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Restraints on a Bend at 30º and 60º

You can define up to three nodes at any angle on the bend curvature, presuming the points
are more than 5º apart. Restraints can be modeled on any of these nodes. If necessary, one
of the points can be at the 0º point on the bend, which is the bend near point.

The To node of the bend is placed at the tangent intersection point for geometric construction,
but it is placed at the bend far point for analysis purposes. Consequently, specifying a node at
the bend far-weld point generates an error.

Nodes and angles on the bend curvature can be specified in any order.

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Vertical Dummy Leg on Bends

You can model dummy legs on bends in several ways. The three most common methods
used to model dummy legs are outlined below.

Near/Far Point Method

Easy input

Dummy leg acts along centerline of vertical run

Dummy leg does not act at the proper place on the bend curvature

On Curvature Method

Easy input

Dummy leg acts at the proper place on the bend curvature

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Dummy leg does not act along the centerline of the vertical run

Offset Element Method

Difficult input

Dummy leg acts at the proper place on the bend curvature

Dummy leg acts along centerline of vertical run

The element immediately after the bend must define the downstream side of the
bend. Do not define dummy legs on the element immediately following a bend.

Dummy legs and/or any other elements attached to the bend curvature should be coded to
the bend tangent intersection point. The length of the dummy leg is taken directly from the
DX, DY, and DZ properties defined for the dummy leg of the pipe. There is no automatic
alteration of the dummy leg length due to the difference between the bend tangent
intersection point and the actual point on the bend curvature where the dummy leg acts. Enter
the true length of the dummy leg in the DX, DY, and DZ boxes in the Classic Piping Input
dialog box.

Input and output plots of the dummy leg always show it going to the bend tangent intersection
point.

During error checking, the software generates a warning message for each dummy leg/bend
model. Verify that the warning message description of the bend is accurate.

The bend shown on the left enters from the

top left corner of the control station nodes 80
to 85 and exits horizontally to the right (nodes
85 to 90). The dummy leg is attached near
the 45º point on the bend. The centerline of
the dummy leg should line up with the
centerline of the vertical run of pipe.

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Coding the bend is the same for all

three methods except alpha is not required
for the Near/Far Point Method.

Dummy leg length is equal to the distance

from its base to the bend tangent intersection
point plus the bend radius.

Calculate α from the relation shown on

the following page.

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Enter α on the bend specification

instead of the midpoint.

Calculate the offset distance y = R(1-

sinα).

Add the distance y to the dummy leg

length.

Calculate α and the offset distance x

and y from the figure on the following
page.

Add x and y to the dummy leg length.

Activate the offsets to subtract them

from the dummy leg.

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Vertical Leg Attachment Angle

Horizontal Dummy Leg on Bends

The element leaving the bend must define the downstream side of the bend. Do not define
dummy legs on the element immediately following a bend.

Enter the true length of the dummy leg in the DX, DY, and DZ boxes in the Classic Piping
Input dialog box.

Input and output plots of the dummy leg always show the dummy leg going to the bend
tangent intersection point.

During error checking, the software generates a warning message for each dummy leg/bend
model. Verify that the warning message description is accurate.

Example

Horizontal Dummy Leg on Midpoint of Bend

The dummy leg is defined as a zero weight

rigid supported on one end by a spring can.

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Large Rotation Rods - Basic Model

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.

Large rotation rods can be entered in any direction. Use the Type list on the Classic Piping
Input dialog box, to select the rotation rod: XROD, YROD, or ZROD. After the rotation rod is
selected, the restraint options change as follows:

Gap changes to Len, which is the length of large rotation swing.

Mu changes to Fi, which is the initial load on the restraint if used to model variable
support spring hanger. (Imagine the large rotation rod as providing a bowl in which the
pipe node is free to move.)

Enter large rotation rods only where they are needed. Repeatedly using large rotation rods
when they are not necessary can cause the system to become unstable during the nonlinear
iteration. First, analyze the system without the large rotation rods, and then add large rotation
rods where horizontal movement at support points is greatest. Usually, you should add only
one rod in an area at a time.

The rod angle tolerance is currently set at 1º.

Large rotation is generally considered to become significant when the angle of swing
becomes greater than 5º degrees.

As for any other support, connecting nodes can be used for large rotation rods. Graphically,
the connecting nodes and the restraint node do not have to be at the same point in space.

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There is no plot connectivity forced between large rotation rod nodes and connecting nodes.

The plus or minus signs (+/-) on the large rotation rod determine the orientation of the swing
axis. A positive YROD (+YROD) is equivalent to an YROD and indicates that the concave side
of the curvature is in the positive Y-direction.

Example

The rod pivots about the structural steel support. There is a very short swing arm, so even a
small amount of horizontal movement produces a relatively large swing. The output report for
this restraint shows X- and Y-direction loads.

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Large Rotation Rods - Chain Supports

In the model below, imagine that you want the large rotation to swing only in the plane of the
chain support (the Y-Z plane). The two pipes should move freely relative to each other in the
axial direction (the X-Y plane). To do this, use three restraints with connecting nodes. The first
restraint is the large rotation rod with its connecting nodes. In turn, the first restraint is
connected to the second and third linear restraints, allowing only Y-Z interaction between the
large rotation rod connecting node and the top pipe node.

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Bi-Linear Restraints
Bi-linear restraints are used most often to model soil support where some soil ultimate load
bearing capacity can be calculated. Bi-linear restraints are designated by typing a 2
immediately after the direction in the restraint Type box.

After a bi-linear spring is entered, the restraint options change as follows:

Stif changes to K1, which is the initial stiffness. A value for K1 is optional. If it is left
blank, the software presumes a rigid initial stiffness.

Gap changes to K2, which is the yield stiffness. The software requires a positive value
for K2.

Mu changes to Fy, which is the yield load. The software requires a value for Fy.

Some sub-sea pipeline resistance tests have shown that load carrying capacity drops after
the ultimate load is reached, and displacement continues.

For more information about the use of the spring types used to model underground piping
systems, see Underground Pipe Modeler in the CAESAR II User Guide.

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Characteristics of Bi-Linear Supports

Pipe in a Trench Bi-Linear Restraint Modeling

Estimated Stiffness Models

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Static Snubbers
Static snubbers are translational restraints designed to provide resistance to dynamic loads
such as seismic and wind. Snubbers are activated by checking the Snubbers Active? check
box for the appropriate load case (the one that contains the occasional load) on the Load
Case Options tab in the Load Case Editor. The figure below shows that snubbers will be
active in load case L2 to restrain the pipe against the uniform load.

Static snubbers, or static analysis snubbers, have SNB following the translational direction
that displays in the restraint Type box (located on the Classic Piping Input dialog box). After
you enter a snubber, Gap and Mu are no longer available.

Static snubbers can be directional. That is, they can be preceded by a plus (+) or minus (-)
sign. To model static snubbers, follow the steps below.

1. Run the operating case without defining a snubber.

2. Note the displacements, in all six degrees of freedom, at each snubber location.

3. In the Classic Piping Input dialog box, add each snubber with a distinct CNode.

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4. Place the displacements from Step 1 on all snubber CNodes.

5. Modify the load cases by including D1 everywhere that T1 displays.

6. Activate snubbers in the Load Case Editor for all load cases containing occasional
loads.

Plastic Hinges
The steps in setting up a plastic hinge are illustrated below. The leg from A to B is overheated,
causing bending of the B-D support leg. This example models the plastic deformation at
cross-section E-E. The plastic hinge is formed between nodes 10 and 15. The plastic hinge is
modeled as a zero length expansion joint with rotational bi-linear restraints. The expansion
joint is used to provide translational and torsional rigidity at the plastic hinge junction. 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.

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The yield force is computed using the

following equation:

Fy = SyZ(SF)

Where

Sy is the yield stress

Z is the section modulus

SF is the safety factor

Sway Brace Assemblies

The sway brace is commonly used to allow unrestrained thermal movements while tuning the
system dynamically to eliminate vibration. A sway brace resembles a spring in that it can be
pre-loaded in the cold (installed) position. After pipe thermal growth, it reaches the neutral
position and the load on the system in the operating condition is zero or negligible.

The sway brace is composed of a single compression spring enclosed between two movable
plates. The spring is precompressed a full inch, which provides an initial force that
instantaneously opposes vibration. Any movement from the sway brace neutral position is
opposed by a load equal to the pre-load plus travel from the neutral position multiplied by the
sway brace spring constant. After maximum allowed travel (usually 3-inches in either
direction) is reached, the sway brace locks, preventing additional movement.

Manufacturers typically recommend a specific size sway brace for a given pipe nominal
diameter.

A more specific sway brace selection is possible when the exact restraining force required to
control the piping vibration is known. The energy necessary to control the piping is
proportional to the mass, amplitude of movement, and the force causing the vibration. From
this relation, the exact restraining force required to control the piping vibration can be
calculated and an appropriate sway brace size selected.

After it is selected, the sway brace can be modeled in CAESAR II using a combination of a bi-
linear restraint and a translational restraint:

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In the event that the sway brace is to be installed in the operating condition (or the neutral
position is to be adjusted in the operating position), the modeling in CAESAR II is a little more
complex. In this case, before modeling the sway brace, you must analyze the piping system
without the sway brace to obtain displacements from the cold to neutral operating position:

Run an analysis on the system without the sway brace to obtain the displacements from cold
to operating condition. In the example illustrated below, the assumed CAESAR II-calculated
displacement from cold to operating position is 0.5 inches

Sway Brace Installed in Sustained Condition

In the SUS case, the displacement D2 (vector 2) represents the pre-load in cold position.
Under shutdown conditions, the pipe returns to its cold position and the brace exerts a force
as previously described.

Sustained case restraint loads on sway brace = Pre-Load + Hot Deflection * Spring Rate

Sway Brace Installed in Operating Condition

In OPE, the displacement allows thermal expansion, and the sway assumes neutral position
exerting zero or negligible load on the pipe.

Operating case restraint loads on sway brace =~ 0.0 (does not restrain thermal expansion)

Sway brace opposing compression force (movement occurs after pre-load is overcome).

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Spring Rate: 150 lb../in.

Initial Loading: 150 lb.

Allowed Movement: 3 in.

Calculated Displacement: .5 in.

Be sure to include D2 in the

sustained and operating cases.

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Hangers
This section illustrates methods for incorporating spring hanger design into CAESAR II
models.

For detailed information about using the software to define hangers, see Hangers in
the Boundary Conditions section of the CAESAR II User's Guide. For more information on
how CAESAR II selects hangers, see Hanger Sizing Algorithm in the Technical Discussions
section of the CAESAR II User's Guide.

Hanger Design Basics

Select Model > Hanger Design Control Data from the Classic Piping Input dialog box to
enter values that affect hanger design throughout the model. The hanger control options, with
default values, are shown below. Complete descriptions of each item can be found in the
CAESAR II User's Guide.

To set the default value displayed in the Hanger Table box, specify the Default
Spring Hanger Table setting in Configuration Editor > Database Definitions.

Double-click Hanger on the Classic Piping Input dialog box to define the spring hanger data
for a particular node.

Whenever CAESAR II detects a proposed spring hanger location supporting zero load, the
software displays a warning and does not select a hanger for this location. You can remove
this proposed hanger location from the model to eliminate the warning.

Hanger Design Recommendations

There are instances where the stiffness of the adjacent piping and the hanger location
restraints in the restrained weight case interact unfavorably. This can produce an unwanted
distribution of loads. Often, reducing the stiffness used to compute the hanger loads in the
restrained weight run eliminates these load distribution problems. The default for this stiffness
is 1.0E12. Values on the order of 50,000 or 75,000 have been used successfully to somewhat
relax the system and redistribute these piping loads. You can define the value the software
uses for calculating hanger restrained weight loads in the Hanger Default Restraint
Stiffness configuration setting in Tools > Configure/Setup > Computational Control. .

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The operating case for hanger travel (free thermal case) can be analyzed either with no
spring stiffness at the hanger locations, or with the stiffness of the selected springs inserted at
those locations. In the second case, the software selects the springs through an iterative
process.

You can specify the manner in which the software handles spring hangers in the Include
Spring Hanger Stiffness in Hanger OPE Travel Cases configuration setting in Tools >
Configure/Setup > Computational Control. Inserting the actual hanger stiffness into the
Operating Case for Hanger Travel may give a more accurate result, but may also introduce
convergence problems. Therefore, in the latter case, it is very important that you adjust the
hanger load in the cold case (in the physical system) to match the reported hanger cold load.

Simple Hanger Design

For a simple hanger, no additional input is required. A number of the parameters from the
Hanger Design Control Data dialog box also display on the individual hanger auxiliary data
fields. You can set these parameters globally on the Hanger Design Control Data dialog
box. You can override them locally on the auxiliary data area for each hanger.

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Single Can Design

To indicate that the pipe is supported from below, type a negative number in the Available
Space box on the Hangers auxiliary data tab. This value represents the distance between the
pipe support and the concrete foundation, or baseplate. See the CAESAR II User's Guide for
each of the manufacturer's definitions of available space. If the available space is not a
criterion in the hanger design, type a large negative value (such as -1000).

CAESAR II input plots use a different symbol for these base supports.

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Constant Effort Support Design

To design a constant effort support, type a very small value (such as 0.001) in the Max.
Allowed Travel Limit box.

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Constant Effort Supports - No Design

Entering Constant Effort Support Data

1. Enter the constant effort support load (per hanger) in the Predefined Hanger Data box.

2. Enter the number of constant support hangers at the location.

Do not enter the spring rate or theoretical cold load.

The hanger design algorithm does not design hangers that are completely predefined.

The two constant effort supports at node 377

should carry 10484 pounds each.

Any other data entered on this Hanger dialog box is ignored.

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Existing Springs - No Design

Entering Existing Spring Data

1. Enter the Spring Rate and the Theoretical Cold Load (installation load, on a per
hanger basis) values.

2. Enter the number of Variable Support Hangers at the location.

The hanger design algorithm does not design hangers that are completely predefined. Other
data can exist for the spring location, but this data is not used. Entered spring rates and
theoretical cold loads are multiplied by the number of hangers at this location. CAESAR II
requires the Theoretical Cold (Installation) Load to pre-define the spring where upward
travel is positive.

Theoretical Cold Load = Hot Load + Travel x Spring Rate

Hot Load = 2000 pounds

Cold Load = 2000 pounds +

abs(1.375*590)

= 2811 pounds

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Multiple Can Design

Enter the number of hangers or cans as a positive number in the No. of Hangers at Location
box.

Placing a negative number in that field allows CAESAR II to design up to that number
of hangers at the location.

All other hanger design parameters are still active.

Example

Trapeze Hanger Assembly

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Power Piping Springs The software designs up to three

cans at the support if the load is too high for a
Allowable Load Variation:15%
single or double can configuration.

Rigid Support Displacement Criteria: 0.05

inches

Old Spring Redesign

Use this option to determine if the old spring can still be used. If the old spring can be used,
then the new preset (initial cold load) is determined. If the old spring cannot be used, then a
new spring design is recommended. The old spring is always left in the problem for
subsequent load case analysis. The old hanger information needed for the redesign is:

The hanger table

The number of springs at the location

The old spring rate

The old spring rate is entered in the Spring Rate box under Predefined Hanger Data. The
Theoretical Cold (Installation) Load must not be specified.

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Three springs at node 97. Each have a

spring rate of 1105 pounds/inch.

Cold Spring
See Cold Spring in the Technical Discussions section of the CAESAR II User's Guide for a
detailed discussion of the method for analyzing cold springs.

Example

Cut Short

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Material 18 is used for cut short .

Pipe and Hanger Supported from Vessel

Connecting nodes associated with hangers and cans function in the same way as connecting
nodes with restraints. Connecting node displacements are incorporated in the hanger design
algorithm.

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You must first disable Connect Geometry Through CNodes in the Geometry
Directives category of Tools > Configure/Setup. For more information, see "Configuration
and Environment" in the CAESAR II User's Guide.

Hanger Design with Support Thermal Movement

Type unique connecting node numbers that do not exist on any pipe element on the Hanger
Auxiliary Data tab in the Hanger Connecting Node box. The hanger is designed to act with
one end at the hanger node and with one end at the hanger-connecting node.

Thermal growth of the hanger-connecting node can be specified on any pipe element.

In the following example, the hanger at node 9 is supported from a structural steel extension
(node 1009) from a large vertical vessel. The vessel at the point where the hanger is attached
grows thermally in the plus Y direction by 3.5 inches.

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Hanger Between Two Pipes

A pipe crossing overhead supports part of the weight of the lower pipe. The node on the pipe
passing overhead is typed into the Hanger Auxiliary Data tab as the CNode.

When using hangers with connecting nodes to design springs, be particularly careful that
CAESAR II’s design hot load is accurate. To find the hot load, CAESAR II puts a rigid element
between the pipe node and the support node (which may be another pipe node as in the
example below), and runs a weight case. If both nodes are expected to deflect in the weight
run, then the hanger weight loads are distributed to other parts of the piping system and not to
the hanger. In this case, you may have to estimate the loads on the hanger in an independent
run, and then manually type the operating load on the particular spring hanger with the
connecting node.

If zero-load constant-effort supports are designed for a spring location with a connecting
node, switch the hanger node and the connecting node. In this situation, the pipe node tends

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to deflect downward in the weight run less than the connecting node. To CAESAR II, this
looks like the connecting node is pushing down on the hanger node, thus “holding the pipe
down.” Switching the hanger node and the hanger-connecting node eliminates this problem.

You must first disable the Connect Geometry Through CNodes configuration
option to avoid plot and geometry errors. For more information, see "Configuration and
Environment" in the CAESAR II User's Guide.

The pipe at 65 is supported by a spring

hanger by the pipe at 470.

Hanger Design with Anchors in the Vicinity

Hangers are designed to support a given weight load through a specified travel with a
minimum of load variation. Most often, the weight load is that of the pipe between an anchor
and the hanger.

The travel is the displacement of the hanger node as it thermally expands away from the
anchor. When weight sensitive anchors (such as equipment nozzles) are relatively close to
the hangers (that is, less than four or five pipe diameters in the horizontal plane), the anchors
should probably be freed during the hanger restrained weight run. When the anchors are
freed, the weight of the pipe between the anchor and the hanger should fall almost in its
entirety on the hanger.

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Anchor nodes to be released are typed on the specific Hanger Auxiliary Data tab. The
anchor degrees of freedom are released according to the specified Free Code value. Anchor
degrees of freedom are released for the hanger design restrained weight run only. If the Free
Code value is not specified for an anchor or restraint to be freed, all degrees of freedom
associated with the anchor or restraint are released for the restrained weight solution.

Only linear restraints and anchors can be freed to cause additional weight to be carried by the
hanger. See the following example for more information.

The anchor at 5 is freed in the Y-direction; the anchor at 105 is freed in all directions.

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Hanger Design with User-Specified Operating Load

In certain situations around equipment nozzles, usually where the piping leaving the nozzle is
very complex or very rigid, the hanger design algorithm selects operating loads that are too
small. In these cases, you can override CAESAR II’s calculated operating (hot) loads. The
design algorithm proceeds normally, except that the user-entered hot load is substituted for
CAESAR II’s calculated value for both the hanger design and all post hanger design analysis
load cases.

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In this configuration, freeing the anchors at 5

and 60 did not help the thermal case nozzle
loads. It was postulated that, due to the
stiffness of the overhead branches, the
hanger calculated hot load was not sufficient.
The calculated hot load was 2376 pounds. A
new hot load of 4500 pounds. is tried here.

Simple Bottomed Out Spring

Spring supports that may bottom out have SPR following a translation direction in the restraint
Type box (such as, YSPR for a vertical bottomed-out spring).

When a bottom out spring is entered, the restraint auxiliary screen changes as follows: The
Gap value changes to "x" (the permitted travel), and the Mu value changes to F (the initial
spring load). The direction of permitted travel is assumed to be opposite to the initial load on
the pipe. These definitions are setup to handle vertical springs. Because of this, the "x" and F
inputs are always entered as positive as shown in the following example.

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Simple bottomed-out spring restraints are used most often to conveniently enter predefined
springs into the piping system model. These spring restraints provide a bottoming out
capability that occurs when the spring has exceeded its maximum travel limit.

Always enter the stiffness Stif, the allowed travel "x", and the initial load on the spring F, to
use the bottomed out spring model. If the travel "x" is not entered, it defaults to zero. If the
initial load is not entered it also defaults to zero, and its sign is positive. No hanger should be
entered at the same position as a bottomed out spring.

Known information:

Theoretical Installed Load = 1023 lb.

Spring Rate = 260 lb./in.

Largest Load in Hanger Table = 1690 lb.

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Lift Off Spring Can

Known information:

Theoretical Installed Load = 1023 pounds.

Spring Rate = 260 pounds/inch.

Smallest Load in Hanger Table = 910 pounds.

To get from the installed condition to the initiate lift-off condition the can must displace in the
positive Y direction.

K1 = Spring Rate

FY = 1023 pounds - 910 pounds = 113

pounds

FY = Theoretical Installed Load

Spring Cans with Friction

In many systems, spring cans support portions of the pipe. Spring cans perform the same
function as spring hangers, except that they are below the pipe, pushing up or compressing

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down. The relative movement between the pipe, trunnion, shoe, or cradle and the top plate of
the spring creates frictional forces on the piping system.

The Spring Can with Friction Builder provides simple and comprehensive modeling methods
for spring cans.

Comprehensive Method

Specifies a detailed design of the spring can assembly and considers the spring can
components and the insulation.

Rigid elements

Element 5-10

A rigid element from the pipe center to the pipe outer surface, where length equals the outer
pipe radius.

The rigid element dimensions and process parameters match the parent pipe at the spring
can assembly location node (SL).

Element 10-15

A rigid element from the pipe outer surface to the top of the can at the hanger node (HN). The
element length, h equals:

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The trunnion or shoe height for hot insulated and non-insulated pipe.

The cradle height for cold insulated pipe.

The rigid element dimensions match the parent pipe at the spring can assembly location node
(SL), but the process parameters are ambient temperature and zero pressure. Other
parameters, such as fluid density, mill tolerance, corrosion allowance insulation thickness, and
insulation density are set to zero.

Element 25-30

A rigid element representing the available installation space, H, of the spring can with or
without a stanchion.

The rigid element dimensions match the parent pipe at the spring can assembly location node
(SL), but the process parameters are ambient temperature and zero pressure. Other
parameters, such as fluid density, mill tolerance, corrosion allowance insulation thickness, and
insulation density are set to zero.

Restraints to account for friction

Node 15 with CNode 20

Hanger with horizontal restraints X and Z (when the Y-axis is vertical).

Node 20 with CNode 25

Vertical restraint +Y with the coefficient of friction, µ.

Node 30

Restraint anchor node, ANC. The anchor node represents equipment, a platform, or structure.

While the restraints account for spring can friction, they do not carry piping loads. When
the pipe, trunnion, shoe, or cradle slides on top of the spring can, the frictional loads at
Node 20 are FX and FZ.

Element 25-30 can be omitted by retaining the +Y restraint with µ provided on node 20
and then deleting CNode 25.

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Simple Method

Specifies a simplified, generic design applicable to any hot-insulated, cold-insulated, or non-

insulated condition. Rigid elements are not created.

Restraints to account for friction

Node 45 with CNode 55

Hanger with horizontal restraints X, Z (when the Y-axis is vertical).

Node 55 CNode 60

Vertical restraint +Y with the coefficient of friction, µ.

Node 60

Restraint anchor node, ANC. The anchor node represents equipment, a platform, or structure.

While the restraints account for spring can friction, they do not carry piping loads. When
the pipe, trunnion, shoe, or cradle slides on top of the spring can, the frictional loads at
Node 55 are FX and FZ.

The software bases spring can selection on the height, H. ANC at node 60 is defined at
the distance H from the bottom surface of pipe, even though there are no elements
between nodes 55 to 60.

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Spring Can Restraint Orientation on Skewed Pipe

Pipe orientation may not always align with the global axes. The definition of restraints to
account for friction must match the pipe orientation when using the Comprehensive method.

For the Simple method, spring cans do not need reorientation because the software
does not create rigid elements.

Pipe Skewed in a Vertical Plane

When a pipe skews in the vertical plane, the pipe orientation lies between the vertical global
axis and one of the horizontal global axes. The axial and lateral restraints orientations follow
the global axis directions, projected onto the horizontal plane. Vertical restraint orientation
follows the global vertical axis direction.

The software only considers a pipe skewed in the vertical plane if the angle is greater
than 5º.

The software creates a rigid element from the pipe center to the pipe outer surface, oriented
in the global vertical axis. You must reorient the element for the pipe orientation.

Before manual rotation of After manual rotation of

the rigid element: the rigid pipe radius element:

The Spring Can with Friction Builder creates the rigid elements shown by the dashed red lines
in the below figure. The default orientation of the rigid elements matches the global vertical
axis. To account for the skewed pipe orientation, you must rotate the rigid pipe outer radius

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element so that it connects to the outer pipe surface at a right angle. After rotation, the rigid
elements align as shown by the solid blue lines.

Pipe Skewed in a Horizontal Plane

When a pipe skews in the horizontal plane, the orientation of axial and lateral restraints
follows the local axis direction. Vertical restraint orientation follows the global vertical axis
direction. The figure below shows the rigid elements created by the Spring Can with Friction
Builder as dashed red lines. You do not need to reorient the elements.

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Pipe Skewed in 3-Dimensional Space

When a pipe skews in both the horizontal and vertical planes, the pipe orientation lies
between the vertical global axis and between the horizontal global axes. The axial and lateral
restraints follow the element local axis directions, projected onto the horizontal plane. Vertical
restraint orientation follows the global vertical axis direction. You must only reorient the
element for the pipe orientation in the vertical plane, so the process is similar to that of a pipe
skewed in a vertical plane.

The Spring Can with Friction Builder creates the rigid elements shown by the dashed red lines
in the below figure. The default orientation of the rigid elements matches the global vertical
axis. To account for the skewed pipe orientation, you must rotate the rigid pipe outer radius
element so that it connects to the outer pipe surface at a right angle. After rotation the rigid
elements align as shown by the solid blue lines.

Vertical Pipe

You can create a spring can for vertical pipe by two different methods.

Reorient the rigid elements

Create a comprehensive spring can at the vertical pipe centerline. The rigid elements created
are in line with the vertical pipe centerline, as shown by the dashed red line in the below

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figure. Reorient the rigid elements between the SL and HN nodes to connect at a right angle
to the outer pipe surface. The reoriented elements represent a horizontal trunnion connected
to the vertical pipe, as shown by the solid blue lines in the below figure.

Place the spring can at a horizontal trunnion

Create a horizontal pipe element connected to the vertical pipe to act as a trunnion. Create a
comprehensive spring can at the horizontal trunnion centerline, as shown by the dashed red
lines in the below figure.

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Expansion Joints
This section provides guidelines and recommended best practices for modeling expansion
joints in CAESAR II.

Universal Expansion Joints - Simple Model

The tied universal bellows is designed to absorb movement by lateral deflection only. There is
no axial deflection or relative bending rotations at the joint ends, assuming three or more tie
rods exist.

Instead of lateral spring rates, enter bending spring rates from the manufacturer’s catalog. For
more information about bellows stiffnesses, see Simple Bellows with Pressure Thrust.

Manufacturers publish a wide variety of data for universal expansion joints. In most cases, the
published spring rates are for the universal joint as an assembly. When the lateral stiffness is
given for the whole assembly, the simple or complex models of single bellows can be used. In
this case, the manufacturer must also provide a cumulative assembly displacement limit so
that the piping designer can verify that neither of the bellows are over-extended.

Many universal expansion joint assemblies have stops along the tie bars that are connected
to the center spool-piece. These stops are designed to prevent over-extension of the bellows
and can be modeled in the complex universal joint model. For the simple universal joint
models, you must check the results to verify that the stops are not engaged. Stops should
typically be considered a safety feature and should not be included as a working part of the
design unless particular attention is paid to the design surrounding the stop components.

Check the displacement limits for each of the expansion joints after the protected equipment
loads are within the allowables. You can use the Analysis > Expansion Joint Rating
command to calculate relative bellows movements for evaluating the strength of the
convolution. The Expansion Joint Rating analysis module works only on single bellows,
which requires that you first model and then check each bellows in the universal assembly.

Some manufacturers believe that friction at the tie bar ends, plus other effects, serve to limit
the overall lateral flexibility of this joint. A 10% increase in overall lateral stiffness is sometimes
used to compensate for these frictional effects.

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The complex models are built by running pipe elements, whose diameters are equal to the
diameter of the tie bars and whose wall thicknesses are equal to half of the tie bar diameter,
between rigid elements that extend normal to the pipe axis and from the centerline and to
their intersection with the tie bar centerline.

The weights of the bellows and associated hardware are added to the flange weights on
either side of the bellows. This is particularly true if the expansion joint is between a hanger to
be sized and an anchor.

Field situations, such as loose nuts on tie bars, can be modeled using the complex expansion
joint model.

Descriptions of various universal models are shown below. Each model also includes
example inputs. Only use simple models when you know that both ends of the tie bars are
fixed to the flanges, that is, when there are nuts on both sides of the flange.

The top drawing shows nuts on only one side of the flange at the left end. Model this
configuration with a complex joint model unless you are certain that all tie bars will remain in
tension.

The top model is used when you are given global assembly data for the universal, such as the
assembly lateral stiffness. The second model is used when you are given angular spring rates
for each of the two bellows used in the model.

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When provided equivalent single bellows lateral stiffness for the whole assembly:

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The model below does not show the

addition of any extra
hardware or bellows weights, which could
affect load distribution
and spring hanger design in the area.

When provided individual bellows angular stiffness:

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Tie rods and center spool pieces

should normally be modeled at ambient
temperature.

Pressure thrust is contained by

double-nutted tie rods. Effective ID and axial
restraints can be eliminated.

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This model does not show the

addition of any extra hardware or bellows
weights, which could affect weight load
distribution and spring hanger design in the
area.

Tied Bellows Expansion Joint - Simple Model

Calculate the lateral stiffness for the bellows. The flexible length, or convolution length, of the
bellows is not listed in most expansion joint catalogs. The listed lengths include the rigid end
pieces, such as flanges or pipe ends. Because the transverse stiffness is based on the
flexible length, the flexible length must be known. A very simple way of pulling this value from
the catalog is to examine the incremental increase in overall length of the joint as additional
convolutions are added. With all convolutions the same length, this incremental length can be
used to calculate the total flexible length.

In the following example, the total length of a four-convolution joint is 8-inches, and the total
length of an 8-convolution joint is 12-inches. This means that the extra four convolutions add
4-inches, making the length of all twelve convolutions 12-inches. This also indicates that the
rigid end pieces on this joint of four, eight, or twelve convolutions are 4-inches.

Deff = (4Aeff/p)1/2 = 10.0 in.

KTR = (3/2) (KAX) (Deff/L)2

L = Flexible Convolution Length = 12 in.

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KTR = (3/2) (850) (10.0/12.0)2

= 885.4 lb/in.

Zero-weight rigid element (tie rod):

Build the CAESAR II model of the flexible portion of the expansion joint. The rotational
restraints between nodes 29 and 30 keep the two flanges parallel, which assumes three or
more tie rods. In the field, the tie bars at four points around the expansion joint keep the
flanges parallel.

The flanges and the tie bars form a parallelogram upon lateral deflection.

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Universal Joint with Lateral Controls Stops -

Comprehensive Tie Rod Model
Double-acting restraints with connecting nodes and gaps are used to model stop gaps along
the tie bars. Stops along the tie bars are installed to restrict lateral motion at each end of the
universal joint.

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The following groups illustrate the method used to construct the universal joint with lateral
stops shown above. Only the right-side tie rod elements are shown below.

— Standard pipe elements —

34-36 / 36-38

— Rigid flange elements —

30-32 / 40-42

— Bellows elements —

32-34 / 38-40

— Rigid elements from the pipe to the tie bar centerline —

(Normal to the pipe axis)

30-1030 / 36-1036 / 42-1042

— Tie bar elements —

1003-1002 / 1002-1001

— Restraints with connecting nodes —

RESTR NODE=1001 CNODE = 1042 TYPE = +Y , X , Z

RESTR NODE=1002 CNODE = 1036 TYPE = Y w/gap=1.5 , X , Z

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Hinged Joint
Hinged joints use a zero-length expansion joint with rigid axial, transverse, and torsional
stiffnesses. The bending stiffness equals the bending stiffness of the hinge.

You define the hinge directions using restraints and connecting nodes. The restraint line of
action is always normal to the hinge axis.

Manufacturers define hinged joints to take pressure thrust. Verify that the joint manufacturer is
aware of the design loads in the hinges.

Some expansion joint manufacturers believe that the hinge friction can provide considerable
additional resistance to bending. As the axial load that the hinge carries becomes large, the
hinge friction effect increases. You can make approximations to this increase in bending
stiffness by increasing the stiffness of the bellows proportionally to the axial load on the hinge.
The expansion joint manufacturer can help in determining this.

Typical geometries for hinged expansion joints are shown in the following figures:

In the next example, the hinged joint is zero length and is defined between nodes 45 and 46.
X is the hinge axis, meaning that all relative rotations are permitted between nodes 45 and 46
about the X-axis. Nodes 45 and 46 are fixed rotationally relative to each other in the Y-axis.

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The following example shows the input data used for the hinged joint as shown above.

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Slotted Hinge Joint - Simple Model

The hinged joint is modeled using a zero length expansion joint and rigid elements with zero
weight to define the interaction of the hinge geometry. Hinge directions are defined using
restraints with connecting nodes. The restraint line of action is always normal to the hinge
axis.

Elements from nodes 10 to 15 and from nodes 16 to 20 are weightless, 9-inch long rigids.

In the example model shown above, the software presumes the relative rotation at
the hinge about the Y-axis to be zero. The slots on either side provide some limit to this Y
rotation. In most applications of this type, the relative Y rotation is zero because the problem

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is kept planar using guides. A good first pass can be made using the model shown. If the
analysis shows that the RY restraint between nodes 15 and 16 is supporting load, a further
refinement to the model can be made.

Slotted Hinge Joint - Comprehensive Model

The next model is somewhat different from the previous model because of the need to
provide for the non-hinge axis rotation due to the slots on either side of the joint. The
schematic below illustrates the extra input required to incorporate this effect.

Zero weight rigid elements that define the hinge assembly are listed below:

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10 - 15 Normal to pipe axis to centerline of hinge assy.

10 - 35 "

55 - 30 "

55 - 50 "

15 - 20 Parallel to pipe axis to centerline of hinge axis.

35 - 40 "

50 - 45 "

30 - 25 "

The finite length bellows must be defined accurately between nodes 10 and 55. Typically, this
means entering the correct flexible length and using the manufacturer’s axial and lateral
spring rates.

The manufacturer’s published angular spring rates may not be appropriate for use in
finite length expansion joint models.

Tied Bellows - Simple vs. Complex Model

Although there are no strict rules that dictate when to use a simple model or when to use a
complex model, there are some basic guidelines that you can follow.

Complex Model Guidelines Simple Model Guidelines

Use a complex model when any the following Use a simple model when any of the following
conditions exist: conditions exist:

You are investigating a failure. The tie bars are either guaranteed to be
carrying tension or have nuts on either
The pipe diameter and number of
side of the flange and can carry
convolutions become large.
compression, if needed.

The nuts are only on the outside of the

There is no relative rotation of the ends.
flange, allowing the tie bars to only
carry tension.

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You have good values for the load

distribution in the tie bars. Simple
models give no indication of the load
distribution. In cases where the tie bars
combine to resist relative bending of the
joint ends, one pair of tie bars can be in
compression while the other pair is in
tension. This effective redistribution of
load in the tie bars is never observed in
a simple model. When this does occur,
and if the tie bars are very long,
buckling of the rods in the complex
model should be investigated (evaluate
whether the rods can withstand the
compressive forces reported in the
output report).

The single tied bellows is designed to

absorb movement by lateral deflection
only. There is no axial deflection or
relative bending rotations at the joint
ends.

For bellows with only two tie rods, there

can only be rotation in one direction.

Because of the uncertainty of the application, enter the lateral instead of the bending spring
rate from the manufacturer’s catalog.

Add the weights of the bellow and associated hardware to the flange weights on either side of
the bellow. This is particularly true if the expansion joint is between a hanger to be sized and
an anchor.

When using expansion joints, verify that the displacement limits for the expansion joint after
the protected equipment loads are within the allowables. In CAESAR II, you can use the

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Analysis > Expansion Joint Rating command to help compute relative bellow movements
for evaluating the bellow distortion.

You can build simple models of single tied bellows by entering a large axial stiffness. This
axial stiffness simulates the tie bars, preventing relative axial movement of the bellows. You
can model tie rods with a single rigid element along the centerline of the bellow. With zero
weight and rotational restraints, this prevents the ends of the joint from rotating relative to one
another. In reality, the tie bars being offset from the centerline prevent this rotation.

You can build complex models of tied bellows by running pipe elements whose diameters are
equal to the diameter of the tie bars, and whose wall thicknesses are equal to half of the tie
bar diameter, between rigid elements that extend normal to the pipe axis and from the
centerline and to their intersection with the tie bar centerline. For more information on building
complex models, see the Tied Bellows Expansion Joint - Complex Model.

Some manufacturers believe that friction at the tie bar ends, plus other effects, serve to limit
the overall lateral flexibility of this joint. A 30% increase in lateral stiffness is sometimes used
to compensate for these frictional effects. Field situations, such as loose nuts on tie bars, can
be modeled using the complex expansion joint model.

Slip Joint
Large slip joints are usually difficult to install and difficult to accurately model.

Smaller diameter slip joints are telescoping, axial displacement devices that permit
considerable axial displacement of the slip joint ends and moderately rigid resistance to pipe
bending. They are usually categorized as having two annular packing glands that are
separated axially along the joint by a dead air space or by a small bellows sleeve.

The following figure shows the cross-section of a typical large slip joint. The stiffnesses
between nodes 15 and 25 are a function of the packing stiffness for transverse and rotational
relative deformation and of packing stiffness and tightening for axial relative deformation.

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Slip Joint

Typical delta dimensions are:

5 - 10. The distance from the closest guide or support to the end of the joint. The
same values are also used for 25 - 30.

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10 - 15. The effective length of the joint, if known, or the travel expected plus 4-
inches, or a 12-inch estimate, if nothing else is known.

K1 is the spring stiffness for forces below the yield force, FY.

K2 is the spring stiffness (for joint compression) for forces greater than FY. The best
estimate for this resistance is cumulative friction effects of guides and supports given by
the vendor.

K2 =((100)N/(a) (Approximation)

Where (N) is the nominal pipe diameter in inches, and (a) is the thermal expansion at
the operating temperature in inches per 100feet.

FY is the joint friction thrust from the vendor catalog. Typical values are given as 400
pounds multiplied by the nominal pipe size.

Gimbal Joints
Gimbaled joints are designed to resist pressure thrust. CAESAR II recommends that you
verify that the joint manufacturer is aware of the design loads on the gimbals. External loads
are not always given. If axial loads are given, the bellows designer must know whether it
includes or excludes pressure thrust.

You can model the angular-only gimbal as a zero length expansion joint with rigid axial,
transverse, and torsional stiffnesses. The bending stiffness is set equal to the rotational
stiffness specified in the manufacturer's catalog.

CAESAR II recommends that you thoroughly model angular and offset gimbals, as shown in
the following figures. Angular and offset gimbaled joints are usually installed in large diameter
lines where lumped-property assumptions for the bellows may not be within reasonable
engineering accuracy.

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Rigid elements between nodes 105 and 110 and nodes 111 and 115 each contain
half the weight of the hinge mechanism.

Tied Bellows Expansion Joint - Complex Model

In the example shown below, the flexible joint is between nodes 30 and 35. The flanged ends
of the joint are modeled as the rigid elements in nodes 20 to 30 and nodes 35 to 45.
Additional rigid elements, perpendicular to the pipe axis, extend from each flange. The tie
rods are 1-inch in diameter. The following nodal layout and corresponding data input is used
to build a comprehensive model of the tied bellows.

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Weightless rigid elements extend from the

flange centerline to the outside edge of the
flanges where the tie rods are attached. Only
two of eight element data inputs are shown in
these examples.

Tie rod is usually at ambient temperature, but

it is important to specify this correctly.

Dual Gimbal
Dual gimbal joints are two, usually angular-only, gimbaled joints in series in the pipeline.
Putting two (or three) angular-only gimbaled joints together provides the ability to absorb
lateral and possibly axial deformation.

Pipe flexibility software is unable to model the axial-only component of the possible
deformation because it requires large rotation of the expansion joint components.

Use the single angular deformation only gimbals in series with at least one other gimbaled
joint. It is only in series that the angular deformation only gimbal provides for any lateral
movement.

Gimbaled joints are designed to take pressure thrust. Verify that the joint manufacturer is
aware of the design loads on the gimbal. Model each individual angular-only gimbal joint as a
zero length expansion joint with rigid axial, transverse, and torsional stiffnesses. Ensure that
the bending stiffness is equal to the manufacturer's published rotational stiffness term.

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The minimum required distance, or L, between adjacent single gimbaled joints (shown as 8-7
in the following example) is principally a function of the angular and rotational deformation to
be absorbed, the diameter, and the number of convolutions per joint. The following figure
shows a dual gimbal comprised of two angular-only gimbals. The bending stiffness for each
gimbaled joint is 490.0-inches lb./deg.

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Because both expansion joints use

the same stiffness values, it is shown only
once in this example.

Simple Bellows with Pressure Thrust

The numbers used for the expansion joint examples in this topic are for
illustrative purposes only. CAESAR II recommends that you verify all values used from a
qualified technical source.

You can model bellows expansion joints using either a zero or a finite length. When finite
length bellows are used, leave either the bending or the transverse stiffness blank. CAESAR
II calculates the exact stiffness coefficient for the term left blank. If all stiffnesses are defined,
CAESAR II uses the defined data and skips the stiffness calculations. For finite length
expansion joints, leave the Bending Stif box empty and enter the lateral stiffness given by
the manufacturer into the Trans Stif box on the Expansion Joints Auxiliary Data tab in the
Classic Piping Input dialog box.

CAESAR II uses the Expansion Joint Manufacturer's Association (EJMA) equations to

calculate the bending (angular) or transverse (lateral) stiffness of metallic bellows. EJMA
defines these stiffness values as:

Ktr = (1.5Kax)(Deff/L)2 (1)

Kb = (Kax) (Deff)2/8 (2)

Where

Kb = Bending angular stiffness of the bellows

Ktr = Transverse lateral stiffness of the bellows

Kax = Axial stiffness of the bellows

Deff = Effective diameter mean diameter of the bellows

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L = Length of the bellows for all convolutions

Equation (2) above is based on modeling bellows as zero-length where the

expansion joint acts as a hinge.

Because it is possible to leave the Effective ID box blank (zero), CAESAR II uses derived
formulas for the calculation of the bending or transverse stiffness in terms of the other
stiffness, thereby eliminating the effective diameter from the equations.

Kb = (KtrL2/3)(p/180) (3)

Equation (3) has been increased by a factor of 4 from that derived from equations (1)
and (2) above.

or

Ktr = (3Kb/L2)(180/p) (4)

Equation (4) has been decreased by a factor of 4 from that derived from equations
(1) and (2) above.

Bellows were originally modeled as zero-length elements. Finite-length bellows in bending

cause a translation while zero-length bellows do not. For zero-length bellows, hold the
translation of a finite-length bellows to zero while in bending. This requires a bending stiffness
of four times that of the zero-length expansion joint, regardless of the length of the finite-
length bellows. This is similar to the guided cantilever methods.

Most expansion joint manufacturer's catalog values for bending stiffness are still based on
zero-length bellows, while the transverse stiffness is normally based on the finite-length of
bellows. For more information refer to equations (1) and (2) above. For this reason, enter the
transverse stiffness and leave the Bending Stif box blank. CAESAR II then calculates the
proper bending stiffness according to equation (3) and uses this value for the flexibility
analysis. If you enter a value for KTR that does not conform to equation (1), equation (3) uses
the entered value to calculate Kb.

If a catalog value of Kb is used and that value is based on zero-length values,

CAESAR II uses equation (4), which results in one-quarter of the value of KTR.

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For a zero length expansion joint, CAESAR II uses either the preceding or the following
element to determine the axial direction of the bellows stiffnesses. The preceding
element is checked first.

Bellows are very fragile under torsional loading. Accurate torsional stiffnesses and
allowable torsional rotations should be obtained from the vendor.

Systems using untied bellows should either be of very low pressure or adequately
anchored and guided to withstand the possibly large thrust loads developed due to the
unrestrained bellows.

Bellows and any other miscellaneous weights should be added to flanges on either side
of the bellows, or can be added as concentrated forces. This is particularly true when
the bellow is part of a hanger sizing weight calculation.

A zero or blank Effective ID results in a zero pressure thrust. The Effective ID is the mean
diameter of the bellows and is used to find the area for pressure thrust calculations. The total
thrust load is applied at the From and To ends of the bellows and is used to open the bellows
if the pressure is positive. The magnitude of the thrust load is P ´ Aeff, where P is the pressure
in the pipe above atmospheric, and Aeff is the area, found from

Aeff = p/4 ´ (DEff)2

Many manufacturers specify the effective area of the bellows. The Effective ID for CAESAR II
input can be calculated using the following equation:

Deff = [4Aeff /p]½

In the example below, the untied bellows runs between nodes 8 and 9. The elbow at node 11
is anchored to take the thrust load developed in the bellows. The manufacturer's specification
for the axial stiffness of the joint is 5131 lbs/in. with a transverse stiffness of 27058 lbs/in. The
bending stiffness is left blank and is calculated by CAESAR II because the bellows has a finite
length. The pump and the baseplate at node 5 must be able to withstand the large axial force
that develops due to pressure thrust in the bellows.

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Aeff = 69 in2

P = 175 psi

Thrust = 69(175)=12075 lbs. (automatically

applied by CAESAR II)

* The bending stiffness (Bending Stif)

calculated by CAESAR II:

KBend = 1/3KtrL2(p/180) = 984 in-lbs/degree

Pressure-Balanced Tees and Elbows

Pressure-balanced tees and elbows are used primarily to absorb axial displacements at a
change in direction without any associated pressure thrust. Pressure-balanced tees can also
be used in universal type configurations to absorb axial and lateral movement.

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The example below shows the coding of a pressure-balanced tee in a turbine exhaust line.
The bottom side of the tee is blanked off. The tee is a standard, unreinforced fabricated tee.
The tie bars only act in tension.

Universal Joint - Comprehensive Tie Rod

The comprehensive universal joint model involves defining all tie rods and connections
between tie rods and end plates.

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The following groups illustrate the method used to construct the universal expansion joint
model shown above.

—Rigid Elements (Flanges) —

15-17 / 31-33

—Rigid Elements normal to the pipe axis and between the pipe and tie bar
centerlines.

Used at the end where there are nuts on either side of the flange, fixing the tie bar to the
flange:

33-1033 / 33-2033 / 33-3033

—Rigid Elements normal to the pipe axis, and between the pipe and tie bar
centerlines.

Used at the end where there are nuts only on the backside of the flange:

15-1015 / 15-2015 / 15-3015

——Intermediate lateral tee supports (Rigid) —

23-1023 / 23-2023 / 23-3023

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25-1025 / 25-2025 / 25-3025

——Tie bars —

1033-1034-1035-1036

2033-2034-2035-2036

3033-3034-3035-3036

— Restraints with connecting nodes at the tension-only flange end.——

RESTR NODE = 1036 CNODE = 1015 TYPE = -X , Y , Z

RESTR NODE = 2036 CNODE = 2015 TYPE = -X , Y , Z

RESTR NODE = 3036 CNODE = 3015 TYPE = -X , Y , Z

— Restraints with connecting nodes at the intermediate support points.

RESTR NODE = 1035 CNODE = 1023 TYPE = Y , Z

RESTR NODE = 2035 CNODE = 2023 TYPE = Y , Z

RESTR NODE = 3035 CNODE = 3023 TYPE = Y , Z

RESTR NODE = 1034 CNODE = 1025 TYPE = Y , Z

RESTR NODE = 2034 CNODE = 2025 TYPE = Y , Z

RESTR NODE = 3034 CNODE = 3025 TYPE = Y , Z

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Examples
This section provides examples for a variety of design challenges faced by piping engineers.

Reducers
1. Define the reducer length as you would any pipe element.

For eccentric reducers, skew the element so that the To node matches the
centerline of the following pipe elements.

2. Double-click the Reducer check box on the Classic Piping Input dialog box.

If the elements preceding and following the reducer are already defined (such as
if you are inserting this element) then CAESAR II automatically calculates all of the
reducer input data. In that case, leave the Reducer Auxiliary Data tab fields blank.

3. Type the diameter and wall thickness of the pipe that follows the reducer.

You can type nominal diameter and wall thickness and CAESAR II will convert
these to actual diameter and wall thickness if this option is activated in the units
file. (If the Diameter and Wt/Sch boxes on the Classic Piping Input dialog box
convert nominal to actual, then the Reducer Auxiliary Data tab boxes will also
make this conversion.)

Alpha is the slope of the (concentric) reducer transition in degrees. If unspecified,

CAESAR II calculates alpha using 60 percent of the entered reducer length.

Alpha = atan[ (D1-D2) / (2*length of the sloped portion of the reducer*0.6) ]

IGE /TD -12 requires entry of the reducer Alpha as well as R1 and R2 (the reducer
transition radii of the large and small ends).

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Ball Joints
Ball joints can be modeled with zero-length expansion joints, or with restraints and connecting
nodes. When using expansion joints, each ball and socket is defined with one zero-length
expansion joint having rigid axial and transverse stiffnesses and zero bending and torsional
stiffnesses.

If torsional stiffness is small, use a value of 1.0.

Results are invalid for large rotatioN.

Method 1

Zero-Length Expansion Joint

Modeling a ball joint between nodes 20 and

21 Input Specifics
using a zero-length expansion joint.

Ball Joint Diagram

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Node-CNode Model

Method 2

Axial, Translational Restraints

Modeling a ball joint between nodes 20 and

21 Input Specifics
using axial, translational restraints with
CNodes.
The next element starts at node 21 (the From
node).

Ball Joint Diagram

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Node-CNode Model

Jacketed Pipe
Jacketed piping systems are modeled by running the jacket elements directly on top of the
core elements so that the two are concentric.

You can generate a jacketed pipe model by modeling the entire core and then duplicating the
core piping using an appropriate node increment (such as 1000). This produces a second run
of pipe which is modified to build the jacket model. For the jacket, change the pipe size,
temperature, bend radii, and so on, to finish the model. Then, attach the jacket and core by
changing the node numbers and adding restraints.

Typically, the end caps connecting the core to the jacket pipe are much stiffer than either the
core or the jacket. For this reason, node pairs like (10 and 1010), (25 and 1025), (35 and
1035), and (40 and 1040) are often joined by using the same node for each. For example, the
displacements and rotations at the end of the core pipe are assumed to be the same as the
displacements and rotations at the end of the jacket pipe.

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Internal spiders offer negligible resistance to bending and axial relative deformation. Node 15
might be connected to node 1015 by a restraint with a connecting node. For an X-run of pipe,
rigid restraints would exist between the two nodes for the Y- and Z-degrees of freedom.

The +Y support acting on the jacket at node 1020 does not cause any stiffnesses to be
inserted between 20 and 1020. Node 20 is included in the model so that the outside diameter
interference can be checked at the 20-1020 cross sections. If there is any concern about
interference or interference-related stresses at the 20-1020 nodes, then you can use
restraints with connecting nodes and gaps to approximate the pipe-inside-a-pipe with
clearance geometry.

Because CAESAR II constructs the jacketed piping model by associating nodal degrees of
freedom, the software does not know one pipe is inside of another. Therefore, consider the
following items:

If both the jacket and the core are fluid-filled, the fluid density of the jacket must be
reduced to avoid excess (incorrect) weight.

If wind or wave loads are specified, the wind or wave loading must be deactivated for
the core so that the core does not pick up the load.

The core pipe should probably have its insulation thickness set to zero.

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Vertical Vessels
Average diameter of the skirt = 102 + 78/ 2 = 90 inches.

Average temperature of the skirt = 87º F.

Temperature of the vessel = 325º F.

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Nozzle N1:

OD = 10.750.

Wall = 0.5.

Length of Flange = 4.0 inches.

Weight of single flange = 112.

Element 20 to 125 is rigid. The associated diameter and wall thickness are that of the
vessel. The element from 20 to 125 is stiff relative to the vessel. The element from 15 to
215 is stiff relative to the vessel.

The rigid element from 135 to 140 models the flange at the end of the nozzle and is rigid
relative to the nozzle diameter.

The rigid element 225 to 230 models the flange at the end of the nozzle and is rigid
relative to the nozzle diameter.

Local shell flexibilities are defined between 130 and 135 and 220 and 215.

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The example considers the cantilever bending, the shear in the vessel from the skirt,
and the local flexibility of the vessel shell in the vicinity of the nozzle.

Vessel Skirt
The following partial dialog boxes illustrate the modeling techniques used to define the
vertical vessel.

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Vessel

Rigid Elements
These rigid elements are weightless, but they do undergo thermal expansion.

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N1 Nozzle

Flange

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N2 Nozzle

Horizontal Vessels
Horizontal vessel models are built using combinations of straight pipe and nozzle flexibility
simulations (WRC 297). The following example illustrates the most accurate way to define
horizontal vessel flexibility.

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NOZZLE N3:

OD = 12.750.

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Wall= 0.687.

Flange length = 5.0 inches.

Flange weight = 250 lb.

Elements 5 to 6, 6 to 10, 15 to 16, 16 to 20, and 20 to 22 are rigid and the associated
diameter and wall thickness is that of the vessel. These rigid elements are stiff relative
to the vessel.

The rigid element from 26 to 30 models the flange at the end of the nozzle and are rigid
relative to the nozzle diameter.

Local shell flexibilities are defined between the nodes 22 and 24.

The above model considers the flexibility of the horizontal vessel section, the free
translation horizontal restraint at 15, and the local flexibility of the vessel shell in the
vicinity of the nozzle.

The following partial dialog boxes illustrate the modeling techniques used to define the
horizontal vessel.

Vessel Legs Not in Contact with Vessel

Vessel Legs - portion not in contact with vessel T=100Fº, P=0.0psi

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Element 15-16 is identical except for the restraints as shown above.

Vessel Legs in Contact with Vessel

DY = Vessel Radius

Element 16-20 is identical.

Vessel Modeled as Pipe

Vessel Modeled as Pipe

Vessel modeled as pipe (not rigid) P≠0, Fluid Density ≠0

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Zero-Weight Rigid to Nozzle Interface Location

Nozzle Element with WRC 297 Connection Defined

Pipe element (not rigid) P≠0, Fluid Density ≠0

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The vessel flexibilities are calculated and reported during error checking. These values are
used automatically in the analysis. This WRC297 data is available to output in the
Miscellaneous Data report.

Harmonic Analysis (TABLE)

The problem in this example is taken from the following source:

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I. S. Tuba and W. B. Wright, Pressure Vessel and Piping 1972 Computer Programs
Verification An Aid To Developers and Users, The American Society of Mechanical
Engineers, New York, 1972. Problems 6 and 2.

Only the input that is germane to the dynamic analysis is discussed.

This example first analyzes the following model for natural frequencies and then for harmonic
loads imposed on the top of the structure at nodes 8 and 13.

Enter the model as shown and set the material density on the pipe spreadsheet to be zero.
Enter all weights as concentrated masses. Do not enter bends; enter only straight elements.

Member Properties

Pipe Outside Diameter 2.375 in.

Pipe Wall Thickness 0.154 in.

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Elastic Modulus 27.9E+06 psi

Poisson's Ratio 0.3

Run the static case, and then click Dynamic Analysis on the CAESAR II toolbar. The
software opens the Dynamic Analysis dialog box.

On the Lumped Masses tab, you can add additional masses or delete degrees-of-freedom.
In the Eigensolution of larger systems, the deletion of un-needed degrees-of-freedom can be
a very important factor in keeping run times reasonable. Usually, masses must neither be
added nor deleted. The mass of the piping, fluid, and insulation is automatically calculated
and included by CAESAR II. In the current example, the weight of the pipe is zero, and all
masses are concentrated and predefined as lumped masses.

Next, use the Control Parameters tab to modify the control parameters as shown below:

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Setting Frequency Cutoff (Hz) to zero turns it off, and setting Max. No. Eigenvalues
Calculated (0 - Not Used) to 5 guarantees that the first five natural frequencies are included
in the results.

Click Run the Analysis . When the Eigensolution is completed, the calculated natural
frequencies are printed as shown in the figure below.

Close the Dynamic Output Processor.

Click Output > Animations > Mode Shapes on the main window ribbon to view the
animations of the five modes of vibration. The first mode is back and forth along the x-axis,
the second mode is transverse along the z-axis and the third mode is a twisting about the y-
axis. The next two modes are combinations of the previous three.

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Harmonic Analysis of this System

In this example, a 120 Hz electric motor sits on the piping structure and acts:

FX @ 8 = (-95 cos w t ) lb.

FX @ 13 = (95 cos w t ) lb.

The harmonic analysis can determine the largest stress in the small piping structure subject to
these dynamic loads.

The 120 Hz vibration falls between the structural resonant frequencies 115 Hz and
137 Hz. The torsional mode is most likely excited because the sign difference on the forces
promotes a twisting of the structure. The model has already been built, so dynamic input only
requires a slight modification. There is only a single harmonic frequency of excitation to
investigate.

You enter harmonic loads next. The software prompts you for harmonic forces first and then
prompts you for direction. In the example piping system, harmonic forces act at nodes 8 and
13. The forces act in the X-direction with an opposite sign and with a magnitude of 95 pounds.
The force acting at node 8 can be plotted as a function of time as shown in the figure below.

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In the example problem, there are 120 cycles per second.

The following figure shows the harmonic force data input. If necessary, harmonic
displacements can exist in the same problem with harmonic forces. This example has only
harmonic forces.

The same force effect can be achieved by entering +95.0 pounds at each node and
entering a phase angle of 180.0 degrees at node 13.

Calculations for the example problem take less than 30 seconds to complete. You can view
the structure in animated motion or view standard displaced shape plots in the DynPlot
window using the Display Graphical Results option (as shown below). Additionally, harmonic
results, restraint loads, forces, and stresses can be calculated for the maximum
displacements due to the harmonic loads.

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Relief Valve Loads (RELIEF)

The following example analyzes the two relief valve systems, shown below, subject to the
simultaneous firing of both valves.

Process Steam Conditions - 450 psi, @ 650°F

Relief Valve Orifice - JOHNSON #34A-06 2.141 in. ID.

Valve Opening Time - 8.0 milliseconds

Valve Closing Time - 8.0 milliseconds

Relief Duration - 1.0 second

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Relief Valve Example Problem Setup

You can use CAESAR II to compute the support loads, forces, and stresses in the vent piping
system when the relief valves fire simultaneously.

Venting steam stagnation properties are given. On the main window ribbon, click Analysis >
Piping > Dynamic Analysis to open the Dynamic Analysis dialog box. Click Relief Load

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Synthesis to compute the maximum thrust load magnitude at the vent pipe exit. This
dynamic load acts downward at the vent elbow nodes 65 and 100. Venting lasts for
approximately one second, and the opening and closing time for the relief valve (as provided
by the manufacturer) is 8.0 milliseconds. A static load case is run first to perform spring
hanger sizing at nodes 20 and 22. The static load case #3 is the operating case and is used
to set the nonlinear restraints for the dynamic analysis.

CAESAR II Gas Thrust Load Calculations

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The spectrum table name is arbitrarily selected as Relief and is defined as having a
Frequency range and a Force-Multiplier ordinate. A # sign precedes the name in the
spectrum definition because the shock table is to be read from an ASCII file. The spectrum
definition is shown as it appears in the Dynamic Analysis dialog box is shown below:

The DLF Spectrum Generator builds the ASCII file, Relief, which contains the relief valve
spectrum table. You must define the filename, maximum table frequency, number of points,
and the time-history waveform. In the example shown below, a maximum frequency of 33 Hz
and 20 data points are used to generate the table.

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The points in the time history waveform are entered as shown below. These points represent
the opening of the valve, its one-second vent time, and its closing.

The resulting DLF Spectrum is shown below.

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The Frequency versus Dynamic Load Factors is written to the file Relief. Click Save to File,
and then click OK to close the Spectrum Table Values dialog box.

The thrust loads act at points 65 and 100. These loads are defined on the Force Sets tab and
are entered as shown below.

There is only a single load case defined on the Spectrum Load Cases tab as follows:

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Only one static/dynamic combination case is defined. It is the combination of the sustained
static load case with the dynamic load case. This is defined on the Static/Dynamic
Combinations tab as follows:

Only one item needs to be set on the Control Parameters tab. It defines the static load case
for setting the nonlinear restraints. In the following example, the setting is 3 (line 1).
Alternatively, you can set the modal combination method (line 11) to ABS instead of SRSS to
produce conservative results.

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Relief Valve Loading Output

There are four key reports for a relief valve analysis:

Mass Participation Report - Shows how sensitive each of the piping system’s modes
is to the relief valve firing. High modal participation factors indicate that the mode is
easily excited by the applied dynamic forces. If subsequent displacement, restraint, or
stress reports indicate excessive dynamic responses, then the modes having high
participation must be dampened or eliminated. After a particular mode is targeted as
being a problem, it can be viewed in tabular form using the mode shape report or
graphically using the animated mode shape plots.

Displacement Report - Shows the maximum possible positive or negative

displacement that can occur at some time during the relief valve’s firing. Values in this
report are always positive.

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Restraint Report - Shows the maximum dynamic load for which the support should be
designed. The top value is the maximum support reaction. The second value is the
largest support reaction due to any one mode. The last number on the left indicates
which mode.

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Stress Report - Shows the maximum dynamic stress due to the relief valve firing.
Stresses from a dynamic shock load case should be combined with the sustained
stresses from a static analysis and the result compared with the code defined
occasional stress for the material.

Participation Factor Report - Shows which modes tend to be excited by the applied
dynamic load.

The following Stress report shows element stresses due to the dynamic relief loads. The top
value is the maximum stress due to the interaction of all the system modes. The second value
is the largest stress due to any one mode. The bottom number on the left indicates which
mode.

In the following examples, the maximum stress at node 5 is 1481 psi. The stress at node 5
due only to mode #1 is 1280 psi.

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The maximum stress at node 40 on elements 40-50 is 6430 psi. The stress at node 40 due to
mode #4 is 3982 psi. Mode #4 is the largest contributor to the stress at node 40.

Support reactions due to the combination of the static sustained and the dynamic solutions
are shown in the following two report samples:

This stress combination can be compared to the B31 code allowables for occasional stresses.

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Dynamic Analysis of Water Hammer Loads (HAMMER)

In this example, the cooling water supply line shown below suffers a pressure surge when the
turbine driven pump drops offline due to a bearing temperature problem. The elbow at node
45 is observed to jump 6 to 8 inches in the X-direction when the turbine trip occurs. To
eliminate the large field displacements associated with the turbine trip, an alternative support
scheme must be designed.

Fluid Properties - 250 psi @ 140° F

Flow Velocity - 6 fps

Water Bulk Modulus - 313000 psi

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SOLUTION

The magnitude of the pump supply side pressure wave, which emanates from the pump
discharge at node 5, can be estimated from

dp = r c dv

Where:

dp = the pressure rise due to the pump’s instantaneous stopping

r = the fluid density

c = the speed of sound in the fluid

dv = the change in velocity of the fluid

The speed of sound in the fluid can be estimated from:

c = [Ef/(r+ r(Ef/E)(d/t))]0.5

Where:

Ef = the bulk modulus of the fluid (313000 psi)

E = the modulus of elasticity of the pipe (30E6 psi)

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d = the pipe mean diameter

t = the pipe wall thickness

r = the fluid density (62.4 lbm/ft3)

ρ + ρ(Ef/E)(d/t) = 62.4 lbm/ft3

[1 + (313000/30E6)(8.62 -0.322)/0.322] = 79.1875 lbm/ft3

c = (313000 lbf/in2)(ft3/79.1875 lbm)(32.2 lbm ft/lbf sec2)(144in2/ft2)1/2 = 4281 ft/sec

For a more detailed discussion and evaluation of the speed of sound, see Piping
Handbook, Crocker & King, Fifth Edition, McGraw-Hill pages 3-189 through 3-191

Apply the previously mentioned equation for the magnitude of the water hammer pressure
wave.

dp = r c dv = (62.4 lbm/ft3)(4281 ft/sec)(6.0 ft/sec)

= (62.4 lbm/ft3)(4281 ft/sec)(6.0 ft/sec)(lbf sec2/32.2 lbm ft)(ft2/144 in2)

= 345.6 psi

There are two distinct pressure pulses generated when a flowing fluid is brought to a stop.
One pulse originates at the supply side of the pump, and the other pulse originates at the
discharge side of the pump. This example only deals with the supply side water hammer
effect, but the magnitude and impact of the discharge side water hammer load should likewise
be investigated when in a design mode.

The time history waveform for both types of water hammer pulses is shown as follows:

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Pod - Discharge pressure

Ps - Source (tank or static) pressure

Pos - Suction pressure (while running)

dp - Pressure fluctuation due to the instantaneous stoppage of flow through the pump

Pv - Liquid vapor pressure at flow temperature

There is an unbalanced load on the piping system due to the time it takes the pressure wave
to pass successive elbow-elbow pairs. The magnitude of this unbalanced load can be
computed from:

F unbalanced = dp x Area

The duration of the load is found from t = L/c, where L is the length of pipe between adjacent
elbow-elbow pairs. For this example, the elbow-elbow pairs most likely to cause the large
deflections at node 45 are nodes 45-75 and nodes 90-110.

The rise time for the unbalanced dynamic loading should be obtained from the pump
manufacturer or from testing, and it can be determined from graphs such as those shown
above. For this example, a rise time of 5 milliseconds is assumed.

CALCULATIONS

L 45-75 = 7 + 4(20) + 4 = 90 ft.

L 90-110 = 3(20) + 15 = 75 ft.

Area = P/4di2; di = 8.625-(2)(0.322) = 7.981 in.

Area = P/4(7.981)2 = 50.0 in2

F unbalanced = dp x Area = (345.6) (50.0) = 17289 lbf

t duration = L/c

= (90)/(4281) = 21 milliseconds, on leg from 45 to 75

= (75)/(4281) = 17.5 milliseconds, on leg from 90 to 110

t rise = 5.0 milliseconds

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Because the piping in this example is ductile low carbon steel, the major design variable is the
large displacement. The problem is assumed to be solved when the restraint system is
redesigned to limit the large displacements due to water hammer without causing any
subsequent thermal problem due to over-restraint.

1. Generate the DLF spectrum files as shown in the following examples.

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2. Define the spectrum on the Spectrum Definitions tab:

3. Define the force sets on the Force Sets tab.

Three spectrum load cases are of interest in this example: each spectrum separately
and the two of them in combination.

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The sustained static load case is now combined with each dynamic load case for code
stress checks. For operating restraint loads, the static operating case is combined with
each dynamic load case, if necessary.

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4. Set the options on the Control Parameters tab as shown below:

Notes for Analyzing Water Hammer Loads

On the pump or valve supply side, the magnitude of the pressure wave is calculated as
shown in this example using the following formula:

dp = ρ c dv

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On the pump or valve discharge side, the maximum magnitude of the pressure wave is the
difference between the fluid vapor pressure and the line pressure.

On the supply side, a positive pressure wave moves away from the pump at the speed of
sound in the fluid. The magnitude of the pressure wave is equal to the sum of the suction side
pressure and dp.

On the discharge side, a negative pressure wave moves away from the pump at the speed of
sound in the fluid. The maximum magnitude of this negative pressure wave is the difference
between the pump discharge pressure and the fluid vapor pressure. After the pump shuts
down, the pressure at the discharge begins to drop. The momentum of the fluid in the
downstream piping draws the discharge pressure down. If the fluid reaches its vapor
pressure, the fluid adjacent to the pump flashes. As the negative pressure wave moves away
from the pump, these vapor bubbles collapse instantly. This local vapor implosion can cause
extremely high pressure pulses. In addition, there can be a fluid backflow created due to the
rapid drop in pressure. In this case, the backflow slap at the idle pump can be accentuated by
the collapse of created vapor bubbles, resulting in an extremely large downstream water
hammer loading.

Water hammer loadings cycle to some extent. The pressure wave passes through the system
once at full strength. Reflections of the wave can then cause secondary pressure transients.
Without a transient fluid simulation or field data, the usual procedure is to assume one or two
significant passes of the pressure wave.

Where critical piping is concerned, or where the maximum loads on snubbers and restraints is
to be computed, the independent effect of a single pass of the pressure wave should be
analyzed for each elbow-elbow pair in the model. A separate force spectrum load set is
defined for the elbow with the highest pressure as the wave passes between the elbow-elbow
pair. The direction of the applied force is away from the elbow-elbow pair. An individual
dynamic load case is run for each separate force set; combinations of different force sets are
usually not run. This approach is satisfactory when applied to large, hot steam piping systems
that have very few fixed restraints and a high number of low modes of vibration. Extrapolation
to other types of piping systems should be made at the discretion of the piping designer.

CAESAR II does not check the integrity of the piping system due to the local increase in hoop
stress that occurs as the fluid pressure wave passes each pipe cross-section. Slowing the
mechanism that tends to reduce the flowrate can reduce the magnitude of the water hammer
loads. In the case of valve closing, it means slowly closing the valve. In the case of a pump

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going off line, it means slowly removing power from the pump. Slowly in each of these
instances can be estimated from:

T = 2L/c

Where:

T = Time of one wave cycle sec.

L = Characteristic length of piping system. This is usually the length between the pump or
valve and the source or sink.

c = Speed of sound in the fluid.

If the pump or valve stops in a time shorter than T, then the water hammer should be
analyzed as shown in this example for instantaneous closure. Calculations for this problem
are given below.

Of primary interest is the largest time segment that must be used to close a valve or bring a
pump flowrate to a halt such that water hammer type pressure pulses are not generated.
Calculations using the lengths of several reflecting systems are made to determine the
variation of the computed Ts. The longest time is for the wave to leave the supply side at
node 5 and move to the tank connection at node 125. This represents a total L of about 270-
feet.

T = (2) (270) ft./(4281)ft/sec = 126 milliseconds

The length through which the wave passes that causes the most trouble is the length between
nodes 45 and 75:

T = (2) (90)/(4281) = 42 milliseconds

If the pump or valve can slow down in greater than 126 milliseconds, the tendency for water
hammer in the piping system is usually abated. If the pump or valve can slow down in greater
than 42 milliseconds then the tendency for water hammer in the 45-75 length is abated.

Water hammer excitation initially produces axial acoustic waves in the steel pipe wall that can
induce locally very high, very short duration forces and stresses. These short duration loads
are usually not a design problem in ductile steel piping systems. Where crack propagation in
welds and material due to water hammer loads is a concern, use the following rules:

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A very high number of natural frequencies must usually be included in the analysis.
Cutoff frequencies of 300 Hz are not unusual. These are the axial natural modes of the
pipe between the excited elbow-elbow pairs. Higher modes must be computed until the
inclusion of extra modes does not produce an appreciable change in the force/stress
response. The maximum frequency cutoff can be estimated using

SQRT (E/r)/L

Where:

E = Pipe material modulus of elasticity

p = Pipe material density

L = Length of a single pipe element in the primary run that is to have accurate stresses
computed due to the passing of the water hammer originated acoustic stress wave.

Calculation of the maximum cutoff frequency for the 45-75 elbow-elbow pair for the 20-
foot pipe lengths is given as follows:

fcutoff = SQRT (E/ρ)/L

= SQRT ((30E6)(32.2)(12)/(0.283))/20

= (202388 in./sec) / (20 ft. 12 in/ft)

= (843.3 rad./sec) / (2 p rad./cycles)

= 134.2 Hz

Alternatively, including the Missing Mass Correction approximates the contribution from
the omitted modes.

The length of any element in the primary axial runs should not be greater than about
ct/4, where c equals the speed of sound in the pipe and t equals the duration of the
water hammer load. Calculation of the greatest element length for the 45-75 elbow-
elbow pair is given as follows:

Lmax = ct/4

= (4281) ft/sec (0.021) sec/(4)

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= 22.5 ft

To get an accurate estimate of the stresses due to the passing of the stress wave in the
pipe, individual element lengths should be smaller than about 20 feet. Shorter duration
loads require shorter elements to monitor the passing of the stress wave.

The inclusion of the response due to the higher modes does not affect the displacement
results (only the force and stress results). Displacement results, such as the 6- to 8-
inches in this example, can usually be computed accurately after the inclusion of the low
frequency modes with participation factors greater than about 0.01.

Water Hammer Loading Output

Mass Participation Report

This report illustrates the sensitivity between each of the modes in the piping system and the
water hammer dynamic loading. High modal participation factors indicate that the mode is
easily excited by the applied dynamic forces. If subsequent displacement reports indicate high
dynamic responses, then the modes having high participation must be dampened or
eliminated. After a particular mode is targeted as being a problem, you can view it in table
format using the mode shape report. You can view it graphically using the animated mode
shape plots.

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Restraint/Force/Stress Reports
If high modes are included, as discussed in Notes for Analyzing Water Hammer Loads, then
these reports give the maximum values of the forces and stresses in the system due to gross
deformation and the propagation of an acoustic stress wave in the pipe. If the high modes are
not included, then these reports give the maximum values of forces and stresses in the
system due to gross deformation alone.

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Displacement Report
This report gives the maximum possible positive or negative displacement that can occur at
some time during the event. Values in this report are always positive.

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Combination Cases
The force spectrum approach to the water hammer problem does not include consideration of
the time relationship between modal or directional maximums. Conservative results can be
guaranteed by taking the absolute summation of both the modal and directional response
properties. Running one load case for each main piping run and a final load case, including all
of the individual load cases, can typically provide a good indication for where problems exist.

In this example, the main piping run between nodes 45 and 75 added the major contribution
to the system dynamic responses. The combination load case, which included the 45-75 and
90-110 contributions together, yielded little extra information.

Solution Summary
A guide and axial limit stop at nodes 45 and 105 produces little increase in thermal stresses,
which were low to begin with, and serves to attenuate the large axial displacements in the line
due to the water hammer load. Loads on this support due to the low mode displacements are
seen to be small. Local, very short duration loads may not be so small. The restraint should
be designed with this in mind.

A few simple design rules are usually sufficient:

Flexible is optimal. The restraint should only be stiff enough to sufficiently attenuate the
low frequency gross deformation.

Areas of local discontinuities, such as the weld of the support to the pipe, should have
extra weld or support plate area. Discontinuities at other restraints in a problem area
should also be reinforced to withstand the local passing of the impact stress wave.

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Dynamic Analysis of Independent Support Earthquake

Excitation (CRYNOS)
This example explains how to model a cryogenic piping system in accordance with B31.3
using specific ground, building, and envelope spectra. The two analyses that are run in this
example assume the pipe (structural steel) supports are rigid and include the flexibility of the
structural steel supports by including the steel frames in the analysis. Finally, compare the
results from the two analyses. The design parameters are:

Ambient temperature: 100°F

Operating temperature: -59°F

Pipe: 8-inches Sch 10S

Insulation: 4-inches 22.3 lb/cu feet

Insulation: 0.232 SG

Columns: W14x82

Beams: W10x12

The isometric of the complete model is shown in the following figure. This drawing shows the
piping, pipe supports, and the structural steel frames

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The following table lists the excitation spectra to be applied to this model:

Ground Response Spectra Building Response Spectra Envelope Response Spectra

Ground Response Building Response Envelope Response

T sec V in/sec T sec V in/sec T sec V in/sec

0.05 0.787 0.05 0.787 0.05 0.787

0.2 7.874 0.2 1.3 0.2 7.874

0.5 21.653 0.5 3.4 0.5 21.653

1 39.37 1 27.3 1 39.37

2 18.89 2 30.4 2 30.4

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3.5 43.7 3.5 21.12 3.5 43.7

5 11.8 5 21.3 5 21.3

10 5.9 10 5.359 10 5.9

The necessity for the various spectra can be best understood by investigating the difference
between independent support excitation and uniform support excitation. These excitation
methods are shown in the following figures.

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For the analysis with steel supports, the structural steel must be included as part of the piping
model. Click Environment > Include Structural Input Files. The structural data input is
shown below:

SECID=1, W14 X 82; COLUMN CROSS SECTION

SECID=2, W10 X 12; BEAM CROSS SECTION

MATID=1, YM=29E6 POIS=0.3 G=11E6 DENS=0.283

DEFAULT SECID=1

ANGLE=90

EDIM 1038 1039 DY=15-0; DEFINE ALL COLUMNS

EDIM 1043 1044 DY=15-0

EDIM 1048 1049 DY=15-0

EDIM 1053 1054 DY=15-0

DEFAULT SECID=2

ANGLE=0

EDIM 1039 1040 DZ=-2-0;DEFINE ALL BEAMS

EDIM 1044 1045 DZ=-2-0

EDIM 1054 1055 DZ=-2-0

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FIX 1038 ALL

FIX 1043 ALL

FIX 1048 ALL

FIX 1053 ALL_

The dynamics input for this example is summarized in the following figure:

Details of the dynamics input are shown in the next four figures.

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Only the results for the uniform support excitation case are shown. Using this load case, the
model with and without structural steel supports is compared. The results from these two

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models are shown in the following tables.

With Structure

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Without Structure

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With Structure

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Without Structure

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With Structure

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Without Structure

Results
These comparison tables illustrate the differences that can exist when the structural steel
models are not included in the analysis. In some cases, the results with the structural steel
included are many times higher than the results computed without the structural steel. The
steel models add flexibility to the piping system. More flexibility means lower natural

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frequencies and more modes to be excited by the shock. A comparison of the natural
frequencies of the two models is given as follows:

With Structure

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Without Structure

In the previous table, there are only five extra mode shapes for the system.

The restraint moment at node 55 in the Z-direction is much larger without the steel model than
it is with the steel model. Even though the piping is tied to the steel, the steel frame does not
support much moment in the Z-direction. The steel frame bends slightly about the Z-axis, and
the moment is carried through from the pipe. In the piping only model, the rigid anchor at
node 55 does not rotate about the Z-axis (or any other axis), and ends up carrying the entire
moment load.

Structural Analysis (FRAME)

The following example uses CAESAR II to analyze the braced frame shown below, subject to
the given uniform load and self weight.

Column section data area = 15 in2 inertias = 250 in.4

Column section data area = 10 in2 inertias = 500 in.4

Brace section data area = 5 in2 inertias = 1 in.4

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Material density: 490 pcf

Material density: 200 lb/inches

This example shows how to model a structure using the CAESAR II Structural module. The
figure below displays a single-bay, braced space frame. All beam and column lengths are 50-
inches. This frame is subject to its own weight load as well as a uniform load of 200 pounds
per inch on all of the top-level beams. You need to determine the displacements, reactions,
and element forces for three load cases: self weight, uniform load, and self weight plus
uniform load.

This example illustrates how to use most of the keyword directives in the structural
preprocessor. A standard finite element modeling approach is followed, where the system
nodes are defined first, followed by materials and section properties, elements, and finally the
loading.

Process the Input File

1. In CAESAR II, click File > Open and open the structural file Frame.str.

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Example files are delivered to the [Product Directory]\Examples folder during

installation.

Select Structural(*.str) in the Files of type list.

2. Click Input > Structural Steel.

The Structural Modeler dialog box displays the frame model.

3. Click Save on the Structural Modeler toolbar to error check and save the model.

4. Click Yes in the Save changes to FRAME? message box.

5. Click OK in the Model Generation Status message box.

6. Click File > Exit to exit the structural steel input processor.

7. Click Static Analysis on the CAESAR II toolbar.

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CAESAR II reads the binary files created by the structural preprocessor and displays
recommended load cases in the Static Analysis dialog box.

CAESAR II recommends load cases to satisfy piping code compliance and not
necessarily loads that you would want to use for structural analysis.

8. Edit the load cases as shown in the example below.

Load case 2 (L2) consists only of U1, which is designated as an operating case
(OPE). This is a construction case and is segregated here because it may be interesting
to see the loads produced by the Uniform Load.

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9. Click Run Analysis to begin processing.

The software displays the results for the analysis.

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Dynamic Analysis (NUREG9)

This example analyzes the piping system shown below, subjected to a series of shock
spectra. The example problem, taken from NUREG/CR -1677, BNL-NUREG-51267, VOL II,
August 1985, is one of the NRC benchmark problems run to verify the dynamic capabilities of
CAESAR II. The detailed input is neither shown nor discussed in this example. The required
input files are located in the [Product Directory]\Examples folder.

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NRC Example NUREG 9

NRC Example NUREG 9

The example is a three-branch system, composed of 20 pipe elements and 14 support

elements. The support elements are divided into four groups that correspond to four distinct
input excitation spectra sets. This example demonstrates the independent support motion
feature of CAESAR II. In modeling this problem, the 14 support elements are input as
restraints with stiffnesses. All bend elements include a node at the "near" point to ensure
mass and stiffness computations consistent with the NRC example. In addition to the pipe
density, there is a single lumped mass applied at node 18. In this example, the contributions
from the pseudo-static anchor point displacements are not included. The three solutions
presented represent the following:

Envelope spectrum; spatial then modal combinations

ISM (independent support motion); directional, spatial, then modal combinations using
SRSS

ISM directional, spatial, then modal combinations using ABS

NRC Example Problem 2A

NATURAL FREQUENCY REPORT (Hz)

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MODE NRC CAESAR II

1 9.360 9.362

2 12.71 12.708

3 15.38 15.379

4 17.80 17.800

5 21.60 21.606

6 25.10 25.102

7 32.03 32.039

8 38.07 38.075

9 40.29 40.299

10 48.90 48.905

11 57.51 57.524

12 61.50 61.510

13 62.54 62.550

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14 69.35 69.359

15 77.44 77.456

16 78.88 78.893

17 101.7 101.731

18 103.6 103.598

19 108.0 107.983

20 115.1 115.116

21 135.2 135.265

22 155.2 155.244

23 160.6 160.626

24 203.8 203.820

25 209.9 209.957

Source: NRC BULLETIN NUREG-51267 VOL.II 1980.

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TRANSLATIONS (in)

DX DY DZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

2 .0105 .0105 .0 .0 .0250 .0250

4 .0431 .0431 .0049 .0049 .0907 .0907

6 .0475 .0475 .0253 .0252 .0327 .0327

8 .0280 .0280 .0379 .0379 .0491 .0491

10 .0108 .0107 .0249 .0249 .0631 .0631

12 .0285 .0285 .0186 .0186 .0633 .0633

14 .0849 .0849 .0085 .0085 .0635 .0635

16 .0476 .0476 .0001 .0001 .0402 .0401

18 .0286 .0286 .0318 .0318 .0421 .0421

20 .0131 .0131 .0095 .0095 .0001 .0001

Source: Problem 2A NRC BULLETIN NUREG-51267 VOL.II 1980.

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ROTATIONS (deg)

RX RY RZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

2 .0457 .0457 .0260 .0260 .0190 .0190

4 .0515 .0515 .0688 .0688 .0269 .0268

6 .0389 .0389 .1012 .1012 .0268 .0267

8 .0309 .0309 .0950 .0949 .0217 .0217

10 .0201 .0201 .0289 .0289 .0203 .0203

12 .0105 .0105 .0328 .0328 .0224 .0224

14 .0102 .0102 .0514 .0511 .0299 .0299

16 .0359 .0359 .0496 .0496 .0476 .0476

18 .0105 .0105 .0343 .0343 .0128 .0127

20 .0215 .0214 .0273 .0273 .0090 .0090

Source: Problem 2A NRC BULLETIN NUREG-51267 VOL. II 1980.

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SUPPORT FORCES (lb)

FX FY FZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

1 90 90 65 64 177 177

7 0 0 0 0 708 707

9 446 445 0 0 0 0

11 0 0 206 206 0 0

13 0 0 164 164 0 0

15 188 187 188 187 263 262

17 58 58 198 197 103 103

21 378 377 192 191 245 245

Source: Problem 2A NRC BULLETIN NUREG-51267 VOL. II 1980.

NRC Example Problem 2B

TRANSLATIONS (in)

DX DY DZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

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2 .0064 .0064 .0002 .0 0158 0158

4 .0267 .0267 .0031 .0031 .0574 .0574

6 .0295 .0295 .0162 .0162 .0207 .0207

8 .0170 .0170 .0242 .0242 .0311 .0311

10 .0029 .0029 .0152 .0152 .0399 .0399

12 .0103 .0103 .0110 .0110 .0400 .0400

14 .0530 .0530 .0053 .0053 .0401 .0401

16 .0301 .0301 .0001 .0001 .0255 .0255

18 .0103 .0103 .0187 .0187 .0267 .0267

20 .0033 .0033 .0057 .0057 .0 .0

Source: Problem 2B NRC BULLETIN NUREG-51267 VOL. II 1980.

ROTATIONS (deg)

RX RY RZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

2 .0289 .0289 .0165 .0165 .0116 .0116

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4 .0326 .0326 .0435 .0435 .0172 .0171

6 .0247 .0247 .0641 .0640 .0171 .0171

8 .0199 .0199 .0599 .0598 .0132 .0132

10 .0134 .0134 .0075 .0075 .0120 .0120

12 .0071 .0071 .0204 .0204 .0134 .0134

14 .0062 .0062 .0307 .0307 .0184 .0184

16 .0228 .0228 .0276 .0276 .0301 .0301

18 .0070 .0070 .0208 .0208 .0079 .0079

20 .0128 .0128 .0074 .0074 .0053 .0053

Source: Problem 2B NRC BULLETIN NUREG-51267 VOL. II 1980.

SUPPORT FORCES (lb)

FX FY FZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

1 53 53 46 46 113 112

7 0 0 0 0 441 440

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9 257 256 0 0 0 0

11 0 0 123 123 0 0

13 0 0 98 98 0 0

15 111 111 111 111 156 155

17 32 32 124 123 66 66

21 103 103 114 113 116 115

Problem 2B NRC BULLETIN NUREG-51267 VOL. II 1980.

NRC Example Problem 2C

NRC BENCHMARK SERIES

NRC BULLETIN NUREG-51267 VOL.II 1980.

NRC PROBLEM 2C CAESAR II JOB NUREG9

TRANSLATIONS (in)

DX DY DZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

2 .0090 .0090 .0 .0 .0220 .0220

4 .0373 .0372 .0044 .0044 .0800 .0800

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6 .0411 .0411 .0235 .0235 .0289 .0288

8 .0237 .0237 .0355 .0355 .0434 .0434

10 .0043 .0043 .0227 .0227 .0556 .0556

12 .0148 .0148 .0164 .0164 .0558 .0558

14 .0741 .0740 .0074 .0074 .0560 .0560

16 .0420 .0420 .0001 .0001 .0355 .0355

18 .0148 .0148 .0281 .0372 .0372 .0372

20 .0049 .0049 .0085 .0085 .0001 .0001

Source: Problem 2C NRC BULLETIN NUREG-51267 VOL. II 1980.

ROTATIONS (deg)

RX RY RZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

2 .0402 .0402 .0229 .0229 .0163 .0163

4 .0456 .0455 .0606 .0605 .0244 .0244

6 .0347 .0346 .0894 .0893 .0252 .0252

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8 .0282 .0282 .0835 .0835 .0196 .0196

10 .0197 .0197 .0112 .0112 .0179 .0179

12 .0104 .0104 .0285 .0285 .0199 .0199

14 .0092 .0092 .0429 .0429 .0260 .0260

16 .0318 .0317 .0387 .0387 .0421 .0420

18 .0104 .0104 .0291 .0291 .0116 .0116

20 .0191 .0191 .0110 .0110 .0079 .0079

Source: Problem 2C NRC BULLETIN NUREG-51267 VOL. II 1980.

SUPPORT FORCES (lb)

FX FY FZ

NODE NRC CAESAR NRC CAESAR II NRC CAESAR II

II

1 76 76 70 69 156 155

7 0 0 0 0 607 607

9 350 350 0 0 0 0

11 0 0 184 184 0 0

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13 0 0 146 146 0 0

15 151 151 151 151 212 211

17 45 45 169 168 91 90

21 152 151 170 169 158 157

Source: Problem 2C NRC BULLETIN NUREG-51267 VOL. II 1980.

Omega Loop Modelling (OMEGA)

The Omega expansion loop consists of a series of back to back 135 degree bends. This
example illustrates how to generate a piping model of an Omega loop according to the
following sketches.

Pipe: 3-inches, standard wall

Bend radius: 24-inches

Material: Low carbon steel

Temperature: 200°F, 300°F, 400°F

The example uses an Omega loop as shown below. The given dimensions are the 6-ft 10-in.
height, the 2-ft bend radius, and the bend angles of 135° and 270°. Using this information,
you can derive the other dimensions shown in the following figure.

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Equation 1: Figure 1

When coding a series of back-to-back bends, it is important to remember that the delta
dimensions should be measured from the tangent intersection point (TIP) to the tangent
intersection point.

For more information about the proper coding of bends, see Bends.

Figure 2 shows the node points, which are coded on the Classic Piping Input dialog box to
model the Omega loop. The model is anchored at nodes 1 and 35. The first bend (lower left
bend) spans between nodes 5 and 10. The TIP 10 is to the far right of the bend. For analysis
and output, the actual location of node 10 is at the far weld line, as shown in Figure 3.

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Equation 2: Figure 2

The second bend (upper left bend) spans between nodes 10 and 15. Because you can code
TIP to TIP, the delta coordinates entered in the Classic Piping Input dialog box are the X and
Y distances between nodes 10 and 15 (Figure 2). The actual location of node 15 is at the far
weld line, shown on Figure 3. Node 15 is the TIP for this bend and lies to the left of the pipe.

The third bend (upper right bend) spans between nodes 15 and 20, where node 20 is the TIP.
In coding from TIP to TIP, only a delta x is required. Figure 3 shows the actual location of
node 20 on the pipe.

The fourth and final bend (lower right bend) spans between nodes 20 and 25. In this case, a
delta X and a delta Y are required. The actual location of node 25 is shown on Figure 3. The
element from 25 to 30 is a straight element necessary to finish off the bend.

A bend in CAESAR II requires an element beyond the far weld line to determine its
orientation.

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Equation 3: Figure 3

Below is an input listing for the model. The delta dimensions shown were obtained from
Figure 1. Three additional, equally-spaced points are located on each bend.

This example requires a change in the CAESAR II Configuration Editor to allow the
error checker to accept large angle (> 95°) bends. \

Click Tools > Configure / Setup to open the CAESAR II Configuration Editor. In the
Categories pane, click Geometry Directives and set Maximum Allowable Bend Angle to
135.

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Jacketed Piping (JACKET)

This example guides you through the modeling techniques used in the analysis of jacketed
piping systems. Where applicable, various alternatives are discussed that can benefit specific
systems or problems.

The piping system to be analyzed is shown in the following figure. It consists of an 8-inch,
schedule-40 crude oil line and a 12-inch, schedule-40 steam jacket. The section of piping
from the pump to the valve is completely jacketed, while the section from the valve to the
vessel has only the straight sections jacketed. This variation in the jacket is used to illustrate
the two common types of jacketed systems. The core pipe is supported in the jacket using
spiders. These spiders provide translational restraints in two directions, normal to the axis of
the pipe. For this system, the spiders are located at each elbow weld line and in the straight
runs such that the spider spacing does not exceed six feet. For this system, both the jacket
and the core are low carbon steel.

In some systems, the jacket and the core consist of different materials. This condition
must be modeled very carefully because the thermal growth in the core is different from the

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thermal growth of the jacket. Improper axial restraints in such a system can cause extremely
large loads in the pipe.

Modeling Plan
The first step in modeling any system is to consider the most efficient way to create the input
and, more importantly, how to best review the results. After you determine how to best review
the results, you can define the input node numbering scheme. Based on the node numbering
scheme, you can then decide how to generate the model to take advantage of the various
rotate, duplicate, and include options.

For this example system, the core piping is modeled using node numbers from 1000 to 1999,
and the jacket is modeled using node numbers starting at 2000. Additionally, similar locations
on the two systems will have the same base node number, that is, nodes 1110 and 2110
describe the same point on both the core and the jacket. Setting up the node numbers in this
manner enables one of the systems to be generated from the other, using either the duplicate
or the include options of the input preprocessor. You can also view the system individually in
the plot by the Range command and breaking the model at node 1999. The other advantage

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to this numbering scheme is that when reviewing the output, you can immediately tell from the
node number whether the point in question belongs to the core or the jacket.

Although not necessary for a small system such as this, additional node number ranges can
be defined to differentiate parts of the model. To illustrate, the following additional constraints
can be placed on the node numbers. The ground level piping will have nodes in the 100-400
series, while the second level piping will have nodes in the 500-900 series. For example,
node 1110 will be a core node at ground level and node 2550 will be a jacket node on the
second level. To indicate locations where external supports are applied to the system, node
numbers will end in 5; all other points will be multiples of 10. Similar node numbering
schemes can be used to differentiate branches from headers, pipe from structural steel, and
various line sizes. Starting the modeling process with a clearly defined plan can ease both
input verification and output review. For example, consider reviewing the input for this system
and finding a spring hanger at node 1530. You can quickly recognize this as an error because
the 1000 series nodes make up the core piping and cannot use spring hangers. Additionally,
support node numbering should end with a 5.

Node Layout
The system as defined in the preceding figure consists of nine segments of piping. Each
segment is shown in the following figure with the node numbers assigned to the various
points for the core piping. Each segment is discussed individually.

The term segment is used solely to assist in discussing this example.

CAESAR II does not require the segregation of a piping system into segments. There
are no such input requirements or restrictions in CAESAR II.

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Segment A - This segment runs from the pump to the first elbow. Because this section
is at ground level, the 100 series nodes are used. Because the pump acts as an anchor,
the start node of this segment ends in 5, so the pump is assigned node 1105. The length
of the segment requires an intermediate node point for a spider, so node 1110 is
assigned 5-feet from the pump. Nodes 1120 and 1115 are assigned to the elbow. The
positive Y support is not at node 1115 because 1115 is part of the core piping. The
positive Y is applied at node 2115 (the jacket), so we assign the 5 to this node point.

Segment B - This segment is the six-foot vertical section, beginning with the elbow at
node 1120. This section can be modeled by coding to the top elbow and assigning
nodes 1500 and 1510. The 500 series nodes are used here because the 2nd level
piping is now being modeled.

Segment C - The first horizontal run in the 2nd level requires a node at mid-span to
accommodate a spring hanger (on the jacket). This mid-span node divides the segment
into two 9-foot lengths, which exceed the maximum spider spacing of 6-feet. Therefore,
the eighteen-foot span is divided into four elements, each one 4-feet, 6-inches. The
nodes assigned are 1520, 1525 (for the hanger location), and 1530. The segment is
finished off with the elbow modeled by nodes 1540 and 1550.

Segment D - This horizontal segment in the 2nd level is modeled using nodes 1560,
1570, and nodes 1575 and 1580 at the elbow. The nodes 1560 and 1570 are for
spiders, while 1575 is a hanger location

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Segment E - This horizontal segment contains the valve. Nodes for this segment are
1590, 1600, 1610, and 1615. Node 1615 terminates the elbow and is also a hanger
location. The element from 1590 to 1600 should be declared rigid with a weight of 452
pounds. Starting with the elbow at nodes 1610 through 1615, all of the elbows are
modeled as individual elements. This eases the subsequent coding of the jacket. The
elbows in this part of the model consist of two straight pieces of pipe, equal in length to
the radius of the elbow.

Segment F -The third horizontal leg of the expansion loop is modeled using nodes
1620, 1630, 1640, and 1650.

Segment G -The last horizontal run of the 2nd level is modeled using nodes 1655,
1660, and 1670. Node 1655 is a hanger location.

Segment H - The second vertical section of piping returns the system to ground level.
The only additional nodes required for this section are for the elbow at nodes 1130 and
1135. Node 1135 is a positive Y location on the jacket.

Segment I - This is the last segment that terminates at the vessel nozzle. The nodes
used to model this segment are 1140, 1150, and 1155.

Core Piping Input

During the input of the above data, make frequent use of the CAESAR II plot facility. Doing so
ensures that the system is being modeled correctly and that any input errors are detected as
soon as possible. The following figure shows a volume plot of the completed core piping, with
node numbers and anchors.

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At this phase of the input, save the input file if you have not already done so. We also
recommend running the error checker at this time because the core piping model serves as
the basis for generating the jacket piping model. If any errors exist in the core, they are
duplicated in the jacket, thus doubling your correction efforts.

The additional data required to finish the model, such as allowable stresses, temperatures,
pressures, and so forth, are contained in the CAESAR II input file, which is delivered with the
software. This data is found in the [Installation Driver]\ProgramData\Intergraph Cas\CAESAR
II\5.30\Examples Jacket._a file.

Jacket Input (1st Half)

There are several ways to obtain the jacket model. The most obvious method is to continue
using the Classic Piping Input dialog box to build the jacket. A second method is to duplicate
the core pipe input file, and then use the CAESAR II include feature to combine the two
models. Another method is to use the List processor and duplicate the necessary elements
from within the preprocessor. The latter method is the one used for this example.

To begin modeling the jacket, click Edit > List. The software opens the List Option dialog
box, which displays all of the applicable input data. Click the Elements tab to view a list of
elements and their associated delta coordinates as shown below:

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For the first half of the jacket, the core piping is duplicated using the steps below. The
duplicated region starts at the pump and ends at the valve.

1. Click in the row for the element from 1105 to 1110.

2. Press Shift and click the row for the element from 1580 to 1590. This is the element just
before the valve.

The software highlights all rows between the two selections.

3. Right-click the highlighted list and select Duplicate.

4. In the Block Duplicate dialog box, click Identical.

5. Click At End of Input to place the duplicate block.

6. Specify 1000 for the node increment, and then click OK.

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CAESAR II duplicates the block and increments all of the node numbers by 1000. This
results in a section of pipe identical to the pipe from 1105 to 1590 with node numbers
from 2105 to 2590.

Three changes must be made to the new section of pipe to obtain the jacket piping. First, the
diameter and wall thickness must be changed to 12-inches, schedule 40. You can use the
List Editor to find the element from 2105 to 2110, and then type new values. Next, you must
also specify the following values: jacket temperature, jacket pressure, jacket insulation, and
jacket fluid weight. Finally, you must change all the jacket bend radii from long to short. The
most straightforward way to do this is to click the Bends tab on the List Options dialog box
to open the Bends list. Then, starting with the bend at node 2120, change the radius from
Long to 12.0-inches. You must make this change to all of the remaining bends.

After the above changes have been made, the first half of the jacket is finished. A volume plot
of the system now shows the core piping overlaid by the jacket piping.

Although the two models are correctly positioned with respect to one another, they
are not connected. All you have done so far is duplicate several pipes. From the standpoint of
CAESAR II, there are simply two discontinuous systems in the same input file. The graphics

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module plots discontinuous systems such that they all start from the same point, which is why
the jacket and core line up properly in this case.

The next step is to correctly connect the jacket to the core and apply any external restraints.
The connection between the jacket and the core piping must model the spiders that align the
two in the real system. These connections can be modeled in CAESAR II using restraints with
connecting nodes (CNodes).

A CNode associates degrees-of-freedom. If a CNode connects two nodes in the Y-

direction, they experience identical displacements in the Y-direction. Use CNodes to restrain
two nodes to each other without restraining them to the "outside world."

The modeling of the connection between the jacket and the core begins at the pump. In the
Classic Piping Input dialog box, enter the restraint field. Then add a restraint at node 1105
with a CNode at 2105 of type anchor. This associates all six degrees-of-freedom between
nodes 1105 and 2105.

Next, add two restraints at node 1110. Both of these restraints have a CNode at 2110, one in
the Y-direction and one in the Z-direction. These two restraints model the spider between the
core and the jacket.

The spider was not modeled using gaps. The actual clearance between the spider
and the pipes is very small, and attempting to numerically model this clearance using
restraints with gaps causes the job to be highly non-linear. Models with gaps at each spider
have convergence problems and are unlikely to reach a solution.

Nodes 1110 to 1120 define the first elbow. Add four restraints to this spreadsheet as follows:

At node 1115, put a CNode of 2115 with Y- and Z-direction restraints

At node 1120, put a CNode of 2120 with X- and Z-direction restraints. These restraints are
perpendicular to the axis of the pipe. Also, at node 2115 there is a positive Y external
restraint. Add this support to the system on the spreadsheet containing node 2115.

Similarly, add the remaining spiders to the model.

An example of the completed input file, JACKET._A, is delivered to the [CAESAR II

Directory]\Examples folder.

When node 1590 is reached, the CNode at 2590 is connected with an anchor. Also add the
spring hangers at nodes 2525 and 2575.

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Aside from the two anchors at the pump and the valve, all of the spider connections between
the jacket and the core are modeled using two perpendicular restraints with connecting
nodes. How are the other four degrees-of-freedom restrained? What keeps this model from
undergoing rigid body motion? These questions can be resolved by considering two points.
First, the jacket is continuous over the core from the pump to the valve. At both of these
points, you have connected all six degrees-of-freedom. Second, the translational restraints
prevent motion in the three translational directions. Additionally, these restraints also prevent
rotation because the jacket is continuous.

Whenever a model is constructed, you must insure that the model, or parts of the
model, cannot undergo rigid body motion. Such a model produces a singular stiffness matrix,
and the solution cannot be attained. An example of such a poor model is a cantilever beam
with a hinge at mid span.

At this point in the data input process, we recommend that you click Error
Check to run the model through interactive error checking. CAESAR II saves the input and
reports the results in the Error and Warnings dialog box. All reported errors should be
corrected before modeling the second half of the piping jacket.

Jacket Input (2nd Half)

Modeling the second half of the jacket is more complex than the first half because the jacket
only covers the straight runs of piping. For this reason, the jacket elements are coded
manually, as opposed to any form of duplication. Although duplicating portions of the model is
feasible, the time required to delete the jacket from the elbows is greater than the time
required to input only the straight sections. By modeling the jacket directly, the restraints for
the spiders can be input as you encounter them.

To start entering the necessary data in the Classic Piping Input dialog box, press Ctrl + End
to go to the last spreadsheet in the model. At this point, click Continue and change the
node numbers to 2600 and 2610, with a DX of 5 ft. Where is the element from 2600 to 2610?
Return to the spreadsheet and temporarily change the diameter of nodes 2600 to 2610 to 24-
inches and try the volume plot. The element 2600-2610 has been positioned at the plot origin
because, at this time, it is not connected to anything. Return to the dialog box and correct the
diameter by changing it back to 12-inches.

To properly connect the jacket to the core, you must add restraints at nodes 2600 and at
2610. At node 2610, add a CNode of 1610 with restraints in the Y- and Z-directions. At node
2600, add a CNode of 1600. Do not associate nodes 2600 and 1600 in the Y- and Z-

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directions. Associating the nodes in such a way allows the jacket to move freely in the X-
direction and to spin about the X-axis, producing an unstable model. This problem did not
exist in the first half of the model because the jacket was continuous over the elbows and the
model was three-dimensional in nature. In the second half of the model, you must ensure that
the appropriate axial and torsional restraints are applied to the jacket. At node 2600, model an
anchor to 1600. This is simpler than modeling separate X, Y, Z, and RX restraints. This
causes the 8-inch line to be physically connected to the 12-inch line in all six degrees-of-
freedom.

The next jacket element covers the core from node 1616 (the end of the elbow) to node 1640.
Node 2615 is anchored to node 1616 with a CNode.

The next two elements, 2620-2630 and 2630-2640, are standard pipe elements with a DZ of
-4.333 ft. Each To node is connected to the corresponding core node with a CNode
associating the X- and Y-directions.

The remaining three sections of jacket are modeled in exactly the same manner. The final
step in the modeling is to add the spring hangers at nodes 2615 and 2655 and the positive Y-
restraint at 2135. The completed model is shown in the following figure.

Completed Jacketed Piping System

An example of the completed input file, JACKET._A, is delivered to the [CAESAR II

Directory]\Examples folder.

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After the input task has been completed, you must error check the job and analyze it for the
specified loading conditions. Check the results to ensure that the system is modeled correctly.
These checks should include the following:

Verify the weight of the core system, the jacket system, and the combined system. You
can use the Sustained Restraint report for this check. Be sure that the jacket pipe fluid
density accounts for the volume lost due to the core. Because CAESAR II does not do
this automatically; you must reduce the density of the jacket fluid accordingly.

Verify that the piping system does not develop large axial loads in the core, the jacket,
or the equipment anchors. This can be caused by improperly over restraining the pipe in
the axial direction or by the effects of thermal growth on dissimilar metals.

Check the displacements at the elbows in the operating case and verify that the core
pipe does not tend to move through the jacket. CAESAR II does not perform
interference checking.

Check the displacements at the spiders where the jacket and the core are connected. In
the direction of the spiders, the displacements should be the same for both the jacket
and the core.

Verify that wind and wave loads, if any are specified, are disabled on the core piping.

Ensure that the insulation thickness of the core pipe is set to zero.

WRC 107
The following example illustrates a comprehensive local stress analysis of a vessel/nozzle
using WRC 107 and ASME Section VIII, Division 2 criteria.

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To determine whether the WRC 107 Bulletin is appropriate for the computation of the local
stress state in the vessel due to external loading, review the geometry guidelines:

D = 120.0 in., T = 0.625 in., d = 12.75 in., t = 0.375 in.

d / D = 0.10625 < 0.33

Dm/ T = (D-T) /T = 191 > 50

In the example, both conditions are satisfied. The actual preparation of the WRC 107
calculation input can now begin. One of the most important steps in the WRC 107 procedure
is to identify the correlation between the CAESAR II global coordinates and the WRC 107
local axes. CAESAR II performs this conversion automatically. You must, however, identify the
vectors defining the vessel as well as the nozzle centerline. The following figure illustrates the
definition of the direction vectors of the vessel and the nozzle.

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Convert Forces/Moments from CAESAR II Global Coordinates to

WRC 107 Local Axes
In order to define a vessel direction vector, you first need to designate the output data points
(A-D), as defined by the WRC 107 Bulletin. The line between data points B and A defines the
vessel centerline (except for nozzles on heads, where the vessel centerline has to be defined
along a direction that is perpendicular to that of the nozzle). Because, in the vessel/nozzle
configuration shown, point A is assigned to the bottom of the nozzle, the vessel direction
vector can be written as (0.0, -1.0, 0.0), while the nozzle direction vector is (1.0, 0.0, 0.0).

The nozzle direction vector is always defined as the vector pointing from the vessel
nozzle connection to the centerline of the vessel.

In the previous figure, there are two nodes occupying the same space at the nozzle/vessel
surface junction: nodes 55 and 56. You can use an anchor at node 55 with a connecting node
at 56 to model the local vessel flexibility as rigid.

If you are not familiar with this modeling approach, see "Piping Input" in the CAESAR
II User's Guide for more details.

You can then replace the anchor with a WRC 297 local vessel flexibility model, and re-run the
job to see the range of loads and displacements that exist in the system around the vessel
nozzle. In either case, the restraint loads forces and moments can be obtained from the

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CAESAR II Restraint report. These loads reflect the action of the piping on the vessel. The
following figure displays the restraint report of the rigid anchor model.

The total sustained axial load on the nozzle may not be reflected in the restraint report. A
pressure thrust load contributes an additional axial load to the nozzle. The pressure thrust
force always tends to push the nozzle away from the vessel. For example, with a pressure of
275 psi over the inside area of the 12-inch pipe, the total P load becomes:

P = -26 - P(A)

= -26 - 275p (122)/4

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= -31,128

If needed, the P load can be adjusted automatically for the input using the WRC 107/297
analysis module. To begin the analysis, click Analysis > Components > WRC
107(537)/297/PD5500 on the main window ribbon. The software first prompts you to create a
new WRC job and then prompts you to enter geometric data that describes the nozzle
(Nozzle Data tab) and the vessel (Vessel Data tab), followed by loadings data (Loads Data
tab).

To do a WRC 297 calculation, click , and a new tab appears on the left side of the
dialog box.

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You can enter up to three sets of loadings representing Sustained (SUS), Expansion (EXP),
and Occasional (OCC) load cases. CAESAR II automatically performs the stress calculation
of each of the load cases consecutively and then performs the WRC 107 stress summation
routine to compare the computed stress intensities against the stress allowables as required
in Appendix 4 of ASME Section VIII, Division 2. The focus in the current example is only on
the sustained and thermal expansion cases. The loads are shown in the figure below. You can
elect to leave any boxes blank if they are not applicable. If a static analysis has been
performed on the system you are analyzing with WRC-107, CAESAR II can import the loads
directly from the output file. To do this, click Import Loads from Job for each load case.
CAESAR II reads in the loads for the nozzle node number that was specified on the Nozzle
Data tab.

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To run the analysis, click Local Stress Analysis on the WRC 107/297 toolbar. The
software opens an output dialog box and displays the processing results.

You can also click View Report Using Microsoft Word on the WRC 107/297
toolbar to perform the initial WRC 107 calculation and summation and send the results
directly to Microsoft™ Word.

After the input echo, the parameters extracted from the WRC 107 figures are printed to this
report. This step is similar to collecting the data by hand. These non-dimensional values are
combined with the nozzle loads to calculate the two normal and one shear stress. The
stresses are reported on the outer and inner vessel surfaces of the four points A, B, C and D
located around the nozzle. CAESAR II provides the normal and shear stresses and translates
them into stress intensities, which can be used for comparisons against material allowables.

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The outputs of the stress computations are shown in the following examples. As the output
shows, the largest expansion stress intensity (117485 psi) occurs at the outer surface of point
B (Bu).

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WRC 107 Stress Calculation for SUStained Loads

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WRC 107 Stress Calculation for EXPansions Loads

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WRC 107 Stress Summations: Vessel Stress Summation at Nozzle Junction

Failed items display in red.

Because the present nozzle loading causes stress intensities that are not acceptable to the
ASME Section VIII, Division 2 criteria, the nozzle loading must be corrected. One option is to
adjust the nozzle loading from its source; another option is to reinforce the nozzle connection
on the vessel side either by increasing the vessel thickness or by adding a reinforcing pad.
You can repeat the same analysis procedure until the final results are acceptable.

After a reinforcing pad is selected, the CAESAR II automatically computes the stress
at the edge of the pad as well.

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Updated June 2022

Document No. DDGL562C0

Copyright
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