Stress Analysis of Pump Piping (Centrifugal) System using

Caesar II

process piping industry uses several pumps in each process unit. Sometimes the
analysis is very critical. In this article I will try to elaborate the method followed for
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
this two pumps are pumped into a heat exchanger. As per P&ID only one pump will
operate at a time, other pump will be a stand by pump. I will explain the stress
analysis methodology in three parts:- a) Modeling of Pump b) Preparation of analysis
Load cases and c) Analysing the output results.

Fig. 1: Sample pump piping model as it looks in Caesar II

A. Modeling of Pump:
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 till some fixed point. Let us
take the example of the outline drawing shown in figure 2.
 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 inch
and element 5000-5020 as 6.19 inch. At node 5020 we will provide fixed anchor.
During modeling of the above elements we need to use line size and thickness as
diameter and thickness of the equipment. Line temperature and pressures as
equipment properties. We have to provide anchor (with cnode) at node 10 for
checking nozzle loads which we will compare with the allowable value as provided in
Fig. 3 below:

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.

B. Preparation of Analysis Load Cases:

Along with normal load cases two additional load cases need to be prepared.
Normally in refinery and petrochemical industry one pump operates and other acts
as a stand by pump. So we have prepare 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 total system in maximum design temperature ( W+T2+P1

OPE)
 Alignment Check Methodology in Piping Stress Analysis using
Caesar II

Alignment Checking this term is quite familiar with piping engineers and all
construction engineers. During piping installation at construction site it is expected
that equipment flange should match perfectly (aligned) with the piping flange so that
during bolting no problem occurs. But achieving that perfect alignment is very
difficult to achieve. If this alignment for rotary equipments are not proper then there
may be several problems in future during operation which may lead to vibration of
equipment/piping system or in some situation equipment failure. American
Petroleum Institute code API RP 686provides the data for acceptable deviation from
the ideal perfect alignment. As per the code if the vertical and horizontal deviation of
piping flange and rotary equipment flange center line is within 1.5 mm and
parallelism (rotation) is within 0.0573 degree then the alignment is accepted
otherwise means to be devised to bring the deviation within those values. While
performing stress analysis of rotary equipment connected piping systems in Caesar II
we can very easily ensure this limitation. The following write up will describe the step
by step method of doing the same.
Alignment check of nozzle flange shall be performed for all Rotating Equipments like
Centrifugal Compressor, Steam Turbine, Centrifugal Pumps, Gear Pumps etc as per
following procedure.
Steps for performing Alignment checking:
Ensure correct weight of the pipe (with proper thickness), Support weight (dummy pipe),
Weight of valves, flanges and any in-line items.
Consider Insulation density carefully (equivalent insulation density to be correctly fed
with insulation & cladding weight, Check insulation on dummies for cold insulated lines).
Model all branch piping (like drip legs etc.) greater than 2 inches.
Discuss with piping lead engineer for requirement of any maintenance flanges (Normally
for steam turbine or centrifugal connected lines the maintenance flange is recommended)
and include it if required.
Minimize the sustained load on equipment nozzle as much as possible during static
analysis run of the Caesar model.
Normal industry practice is to analyse the Alignment checking in separate file. So rename
the static file as Filename_Alignment.C2
Make the equipment nozzle anchor flexible or remove the displacement if anchor was not
modeled.
 Wherever spring support is used, define spring rate and cold load in case of variable effort
spring & Constant effort support load in case of constant effort spring.
After performing the above create one additional load case in Caesar II as mentioned
below:
WNC+H SUS System with spring hanger
WNC SUS System without spring hanger
Set the spring hanger as As designed.(Two load cases can be generated for spring As
designed and rigid condition)
Now run the analysis and check the displacements of the nozzle at the above mentioned
load case and limit them within below mentioned values:
Vertical deflection (Normally DY): +/- 1.5 mm
Horizontal displacement (sqrt sum of DX and DZ): +/- 1.5 mm
Parallelism (sqrt sum of RX and RZ) : 0.0573 degree.
In case the above limitations are not met then re-analyse by readjusting the spring and
other supports and do the simulation.
Alignment check is to be performed for both inlet and outlet lines.
Alignment check must be performed with spring under both in As designed and in
locked condition.
To avoid small misalignment in vertical direction first support from rotary equipment
nozzle is used either a spring support or an adjustable type support.