Stress Analysis of Pump Piping (Centrifugal) System
using Caesar II
whatispiping.com/pump-piping
Anup Kumar Dey
Every power or process piping industry uses
several pumps in each unit. The analysis of
pump connected piping systems is
considered as very critical. In this article, I
will try to elaborate on the method followed
for the stress analysis of a centrifugal pump
piping system. The stress system consists
of typical discharge lines of two centrifugal
pump (Pump A and Pump B). Fluid from
these two pumps is pumped into a heat
exchanger. As per P&ID, only one pump
will operate at a time, other pumps will be a stand by pump. I will explain the stress
analysis methodology in three parts:
1) Modeling of Pump
2) Preparation of analysis Load cases and
3) Analyzing the output results.
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Fig. 1: Sample pump piping model as it looks in Caesar II
Modeling of Pump in Caesar II
For modeling the pump we require vendor general arrangement drawing or outline
drawing. All rotary equipments are modeled as a weightless rigid body in Caesar II. From
the outline drawing, we need to take the dimensions to some fixed point. Let us take the
example of the outline drawing shown in figure 2.
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Fig. 2: Sample outline drawing for a centrifugal pump
From the above drawing, we can get the dimensions for elements 10-5000 as 8.5 inches
and element 5000-5020 as 6.19 inches. At node 5020 we will provide fixed anchor.
During modeling of the above elements, we need to use line size and thickness as the
diameter and thickness of the equipment. Line temperature and pressures as equipment
properties. We have to provide anchor (with a CNode) at node 10 for checking nozzle
loads which we will compare with the allowable value as provided in Fig. 3 below:
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Fig. 3: Allowable nozzle load values as mentioned in Equipment GA drawing
In absence of allowable load value, the Pump design code (API 610 for API pumps, ANSI
HI 9.6.2 for non-API pumps) can be followed for the same.
After the pump is modeled as rigid body the piping modeling need to be done from pump-
piping interconnection flanges.
Preparation of Analysis Load Cases
Along with normal load cases, two additional load cases need to be prepared. Normally in
the refinery and petrochemical industry, one pump operates and the other pump acts as a
stand by pump. So we have prepared load cases as follows:
1. Hydrostatic case (WW+HP HYD)
2. Operating case with both pump operating (W+T1+P1 OPE)
3. Operating case with the total system in maximum design temperature ( W+T2+P1
OPE)
4. Operating case with pump A operating and pump B Stand by (W+T3+P1
OPE)
5. Operating case with pump B operating and pump A Stand by (W+T4+P1
OPE)
6. Operating case with the total system in minimum design temperature ( W+T5+P1
OPE)
Next all normal load cases like static seismic, static wind, etc are to be built as per stress
analysis or flexibility specification.
When pump A is in operating condition and pump B stand by, the normal pipe operating
temperature has to be inserted till Tee connection for pump A and ambient temperature
will be the input for pump B as shown in Fig. 4. Similarly, reverse the input when pump B
is operating.
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Fig. 4: Operating-Stand By Temperature profile for a two-pump system
After equipment is modeled completely start modeling the piping following dimensions
from piping isometric drawings. Try to make a closed system. Normally pump lines are
connected to some vessel, tank or heat exchangers. So it will create a close system. Then
run the analysis to check stresses, displacements and loads.
Analyzing the output Result
Once Caesar completes its iteration process we can see the output results in output
window. At nozzles (the nodes which we anchored with a CNode) we can check the force
values. These values we have to compare with the allowable values. If the actual values are
less than the allowable values then the nozzle is safe. Otherwise, we have the make
changes in supporting or routing to bring the nozzle load values within allowable. A
sample output restraint is provided in Fig. 5 for your reference.
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Fig 5. Typical output results for a two-pump system
As can be seen from the above figure that we are checking nozzle loads in load cases 2, 4, 5
and 6. For rotary equipment, normally nozzle qualification in design or upset temperature
is not required.
Special Consideration for Rotary Equipments
Now we have to make one separate caesar file and we have to check sustained
displacement at the nozzle at WNC (weight no content) case. This checking will ensure
proper alignment of piping flange and equipment nozzle flange. For detailed alignment
check analysis steps, follow this link: https://whatispiping.com/alignment-check-
methodology
Always remember to provide first piping support from pump nozzle as adjustable support
(or a spring hanger support) to aid in alignment.
In the case of 3 pump systems, normally two pumps will be operating and one pump will
be stand by. So input and prepare load cases accordingly. If you have any confusion or
want to add more please write in the comments section.
Video Tutorial for Pump Piping Stress Analysis
The following video explains the pump piping stress analysis methodology for 3 pumps in
details.
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Few more pump-related articles for you..
Cause and Effect of Pump Cavitation
Major Factors Affecting the Pump Performance
NPSH for Pumps: Explanation and Effect
Water Hammer Basics in Pumps for beginners
Mechanical Seals for Rotary Pumps
Pumps & Pumping Systems: A basic presentation
A brief presentation on “CENTRIFUGAL PUMP WITH SPEED CONTROL”
Considerable points while Commissioning and starting-up a Process Pump
Considerable points while installing centrifugal pumps at site to reduce vibration
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