CAESAR II

version 7.00

Need of piping stress analysis:

In order to keep the stress in the piping and fittings with in the code
of allowable stress limits
In order to maintain uniform international code of standards and
specification
In order to check the nozzle loading on the attached equipment with
in the allowable of the manufactures specification
In order to keep the vessel stress at the piping connection with in
ASME Section VIII / WRC allowable levels
In order to calculate design loads for sizing supports and restraints
In order to maintain the piping displacement for interference checks
In order to solve the dynamic problems in piping such as
mechanical vibration, acoustic vibration , fluid hammer , pulsation ,
transient flow and relief valve discharge

Pipeline Analysis:
When the ends of the pipe ends are closed and pipe is
subjected to an internal pressure P there are various stresses that
develop in the pipe. Each element of pipe are subjected to the below
mentioned stresses which act in the direction as shown in the fig.1.
Circumferential (hoop) stress SH
Longitudinal Stress SL
Radial Stress SR

Circumferential or Hoop stress SH :

The effect of this may split the pipe into two halves as shown in
fig.2. The failure of the pipe in two halves in fact is possible across
any plane, which contains diameter and axis of the pipe. Elements
resisting this type of failure would be subjected to stress and
direction of this stress is along the circumference. Hence the above
stress is called Circumferential or Hoop Stress.

Calculation of Circumferential or Hoop stress S H :

If
D = Diameter of the pipe
L = Length of the pipe
t = thickness of the pipe.
Bursting force, FB =Pressure * Area =P * D * L
Resisting force, FR =Resisting metal area* Stress, S H
Equating FB & FR
P * D * L = 2t * L * S H
t = (P * D)/ 2 * SH
or
SH = (P * D) /( 2 * t) ______(1)
This equation is used for calculating the thickness of pipe so as to
withstand pressureP where SH is allowable circumferential stress.

Longitudinal Stress SL :
Considering that the pipe ends are closed and pipe is subjected to an
internal pressure P the pipe may fail as shown in Fig.3.
Elements resisting this type of failure would be subjected to stress
and direction of this stress is parallel to the longitudinal direction of
the pipe. Hence this stress is called longitudinal stress.

Calculation of Longitudinal Stress SL :

Bursting force, FB
Resisting force, FR

=Pressure Area =P * (D * D)/4

= Resisting metal area x Stress, SL
= D t * SL (when t is significantly small as

compared to D)
Equating FB & FR
P * (D * D) /4= D t * SL
t
=(P D)/4 * SL
or
SL
=(P D)/(4 * t)

________ (2)

Radial Stress SR :
Radial stress is a stress in directions coplanar with but
perpendicular to the symmetry axis.
The radial stress for a thick-walled pipe is equal and opposite to the
gauge pressure on the inside surface, and zero on the outside
surface.
The radial stress is always compressive.
Each element of the pipe is subjected to radial stress which acts in
radial direction as shown in Fig.4 and calculated as
SL = P

Need of CAESAR II :
Every Piping system is subjected to different loads during its design
life which develops stresses in the system.
Depending on the stress design basis the system is classified as
stress critical or non- stress critical.
All the stress critical system shall be stress analyzed using software
system (eg.Caesar II) to keep the stresses within the allowable limits
as per the code/standard.

Objective of Stress Analysis:

Structural Integrity

Optimal Design

Operational Integrity

Types of Loads :
The types of loads to be considered in Stress Analysis shall be as
given in below:
o
o
o
o
o
o
o

Thermal Loads at Various Operating Conditions

Sustained load
Seismic loads
Wind Loads
PSV reaction Force
Slug Force
Forces Induced by Surge Pressure

Thermal Loads at Various Operating Conditions :

Analysis Temperature :

Normally the Design temperature (Maximum/ Minimum values as per

Line List) shall be used for thermal analysis.

For those lines having Design temperature greater than 80 deg. C and if
the difference between Operating and Design temperature is more than 25
deg. C, the maximum/minimum Operating temperatures, as obtained
from Process Group, may be used in Stress Analysis in place of the Design
temperature.

In addition to the Maximum/Minimum Design/Operating temperatures,

Piping shall also be analyzed for the Normal Operating temperature.
Analysis Pressure :

Line Design Pressure specified in the Line List shall be considered as

the analysis pressure.

Sustained loads:
Sustained loads to be considered are as given below:
i.
ii.
iii.
iv.
v.
vi.
vii.

Design pressure.
Weight of Pipe and associated components such as Flanges,
Valves, Strainer,
Sight glass etc., mounted on the Piping System.
Weight of Fluid/contents in the piping.
Insulation and cladding weight.
Hydro test loads, if applicable for the line.
Snow load, if applicable

Seismic Loads :
For Projects where Seismic Design is to be carried out, equivalent Static
Seismic Analysis method in Caesar II shall be used to evaluate the
seismic stresses, displacements and loads on the piping system.
If the Seismic coefficient is not provide by the client, then the
calculation of static seismic co-efficient in terms of g based on Project
site-specific data shall be calculated as per relevant codes
(UBC/ASCE/SNIP/others as applicable). In that case, the Seismic
factor calculation document shall be enclosed as an Attachment to the
Project
Stress
Analysis
Design
basis
document.
The normal Operating Temperature shall be used when analyzing for
Occasional loads. Seismic loads shall be considered as acting along the
horizontal axes (both in +ve and in the ve directions, that is, along
North, South, East and West directions), but not acting simultaneously.

Wind Loads:

Wind loads shall be considered for lines with outside diameter 14

NB (including insulation) & above and at Elevation 10 meters &
above from ground level. The normal Operating Temperature shall
be used when analyzing for Occasional loads.
Wind shape factor shall be considered as 0.7. Wind loads shall be
considered as acting along the horizontal axes (both in the +ve and
in the ve directions, that is, along North, South, East and West
directions), but not acting simultaneously.
Wind pressure for the different Elevations shall be specific to the
Project as per the Project Civil/Structural design basis. The same
shall be considered for wind data input in piping analysis.

PSV Reaction Force:

If the Piping System being analyzed consists of PSV (pressure safety

valve), the reaction force due to PSV operation shall be considered
as applicable and a static equivalent method of stress analysis shall
be performed considering the same.
A Dynamic Load Factor equal to 2.0 shall be applied on the valve
reaction force value.
However, in the case of valves of high reaction force values, the DLF
value calculated as per appendix-II of ASME B 31.1 may be used,
based on valve data if provided by Vendor.

Pressure Safety Valves :

Slug Force:
For lines having slug flow regime, as identified by the Process group on P&ID/line list, slug
force shall be considered in the piping stress analysis. Slug force shall be calculated as below:
Fslug = () (A) (V2) [2(1 cos )]1/2 DLF
Where,
F slug = Force due to slug in Newton.
= Density of the slug in Kg/m3,
A = Inside area of pipe cross section in m2,

V = Velocity of moving slug in m/sec.

= inclusion angle at elbow or change of direction
DLF = Dynamic Load Factor (DLF) equal to two shall be used, unless more accurate value is
available.

Slug Force:
Faxial = () (A) (V2) DLF
Forthogonal = () (A) (V2) DLF

Slug properties shall be obtained from Process group.

Equivalent static analysis in Caesar-II shall be performed to
simulate slug loading in piping system, with the slug force
calculated as above.

Forces Induced by Surge Pressure:

The effect of surge on any line, as identified by the Process group or

a specialist agency, shall be considered in piping analysis.
However two concurrent occasional loadings need not to be
considered in piping stress analysis.

Stress Analysis of Underground Piping :

In every process industry there will be few lines (Sewer or drainage

system, Sanitary and Storm Water lines, Fire water or drinking
water lines etc), part of which normally runs underground.
Under ground piping mainly appears for pipeline industry as miles
of long pipe run carrying fluids will be there.
Elements of analysis include pipe movements, anchorage force, soil
friction, lateral soil force and soil pipe interaction.
Special problems are involved because of the unique characteristics
of a pipeline, code requirements and techniques required in
analysis.

 Common materials used for underground piping are Carbon Steel,

Ductile iron, cast Iron, Stainless Steel and FRP/GRP.
Normally these lines does not have high design temperatures (of the
order of 60 to 80 degree centigrade) and only thermal stress
checking is sufficient for underground part.
Input Required for Underground pipeline:
1. Isometric drawings or GA drawings of the pipeline from Piping
layout Department.
2. Line parameters (Temperature, Pressure, Material, Fluid Density,
etc) from process Department.
3. Soil Properties from Civil Department

Underground Piping Model:

Unique characteristics of a pipe line:

High allowable stress: A pipe line has a rather simple shape. It is
circular and very often runs several miles before making a turn.
Therefore, the stresses calculated are all based on simple static
equilibrium formulas which are very reliable. Since stresses
produced are predictable, allowable stress used is considerable
higher than that used in plant piping.
High yield strength pipe: To raise the allowable, the first
obstacle is yield strength. Although a pipe line operating beyond
yield strength may not create structural integrity problems, it may
cause undesirable excessive deformation and possibility of strain
follow up. Therefore, high test line with a very high yield to ultimate
strength ratio is normally used in pipe line construction. Yield
strength in some pipe can be as high as 80 percent of ultimate
strength. All allowable stresses are based only on yield strength.

 High pressure elongation: Movement of pipe line is normally

due to expansion of a very long line at low temperature difference.
Pressure elongation, negligible in plant piping, contributes much of
the total movement and must be included in the analysis.
Soil- pipe interaction: The main portion of a pipe line is buried
underground. Any pipe movement has to overcome soil force, which
can be divided into two categories: Friction force created from
sliding and pressure force resulting from pushing. The major task of
pipe line analysis is to investigate soil- pipe interaction which has
never been a subject in plant piping analysis.

Inputs Required for CAESAR II :

Isometrics
Wall Thickness
Corrosion Allowance
Pressure Rating
Design Pressure
Design Temperature
Test Pressure
Piping Material
Design Code
Support Location

Loads on Piping system:

There are two types of loads which acts on a piping system:
1. Static loads and
2. Dynamic Loads

Basic Load Cases:

Hydro testing Case :
Pipelines are normally hydro tested before actual
operation to ensure the absence of leakage. Water is used as the
testing medium.
Condition for Hydro test case is WW+HP
WW =
Water filled weight
HP =
Hydro test Pressure

 Operating Case :
Pipelines are tested with the working fluid at given
temperature and pressure .
Condition for Hydro test case is W+T1+P1
W
=
Dead weight of the Piping system
P1
=
Maximum Design Pressure
T1
=
Maximum Design Temperature

 Sustained case :
In this load case only the weight of the pipe and
design pressure is considered for calculating the load case. Sustain
loads will exist throughout the plant operation.
Condition for Hydro test case is W+P1
W
=
Dead weight of the Piping system
P1
=
Maximum Design Pressure
Expansion case :
In this load case only the temperature of the pipe
considered for calculating the load case.
Condition for Expansion case is (W+T1+P1 ) (W+P1 )

CAESAR II Different load cases:

Operational

Sustained

Expansion

Steps in Piping Stress Analysis :

1.

Identify the Critical lines from the P&ID based on the criteria
mentioned in the Piping Stress Analysis Design Basis.

2. Prepare a Stress Critical Line list.

3. Categorize the lines as,
Category-1 (Extensive computer analysis required),
Category-2 (Visual Analysis or by Nomo graphs, etc.) and
Category-3 (Non-critical lines)

4. Segregate the Category-1 lines and identify Stress systems.

Segregation should be made in such a way that proper boundary
conditions can be defined for those lines. Also lines which can
affect the behavior of the system significantly should be selected.
Depending on the configurations Category-2 and Category-3 lines
may also be included in the Piping system
5.

Select a system for the analysis based on the priority or project

requirement

6. List down the lines to be included in the system

7. Check if all the parameters of the lines are available,

. Maximum Design Temperature & Pressure
. Operating Temperature & Pressure
. Minimum Design Temperature & Pressure
. Test Pressure
8. Check if any Occasional loading is applicable for the selected
system,
. Wind Loading
. Seismic Loading
. PSV reaction forces
9. Note down environmental Data of the project,
. Ambient Temperature

10. Once the modeling of the system is done in the Caesar-II using all
the above data, next important activity is to formulate the load
cases for which the system is to be analyzed.
11. List down all the possible conditions the selected system may
experience.
12. Load Cases for a piping system is given below,
.
.
.
.

CASE: 1 Basic parameters and no occasional loading

CASE: 2 Basic Parameters with Wind loading
CASE: 3 Basic Parameters with Seismic loading
CASE: 4 Basic Parameters with Wind &Seismic loading

CASE : 1 Basic parameter and no occasional loading :

Following parameters will be used for formulating the load cases,
WW
HP
W
P1
P2
P3
T1
T2
T3

=
=
=
=
=
=
=
=
=

Water filled weight

Hydro test Pressure
Dead weight of the Piping system
Maximum Design Pressure
Operating Pressure
Minimum Design Pressure
Maximum Design Temperature
Operating Temperature
Minimum Design Temperature

Load Cases:
Case No.

Load Case

Stress Type

L1

WW+HP

HYDRO

L2

W+T1+P1

OPE

L3

W+T2+P2 (P1 can be used in this case) OPE

L4

W+T3+P3 (P1 can be used in this case) OPE

L5

W+P1

SUS

L6

L2-L5

EXP

L7

L3-L5

EXP

L8

L4-L5

EXP

L9

L2-L4

EXP

CASE : 2 Basic parameter with wind loading :

Following parameters will be used for formulating the load cases,
WIN1 = Wind Load in +X direction
WIN2 = Wind Load in X direction
WIN3 = Wind Load in +Z direction
WIN4 = Wind Load in Z direction

Note:
Direction is just for example user can use this
terminology for any other direction as per his ease

Load Cases:
Case No. Load Case
L1

WW+HP

Stress
Type
HYDRO

Combination
Type
Algebraic

L2

W+T1+P1

OPE

Algebraic

L3

W+T2+P2 (P1 can be used in this case) OPE

Algebraic

L4

W+T3+P3 (P1 can be used in this case) OPE

Algebraic

L5

W+P1

SUS

Algebraic

L6

W+T1+P1+WIN1

OPE

Algebraic

L7

W+T1+P1+WIN2

OPE

Algebraic

L8

W+T1+P1+WIN3

OPE

Algebraic

L9

W+T1+P1+WIN4

OPE

Algebraic

L10

L6-L2

OCC

Algebraic

L11

L7-L2

OCC

Algebraic

Case No.

Load Case

Stress Type

L12

L8-L2

OCC

Combination
Type
Algebraic

L13

L9-L2

OCC

Algebraic

L14

L5+L10

OCC

Scalar

L15

L5+L11

OCC

Scalar

L16

L5+L12

OCC

Scalar

L17

L5+L13

OCC

Scalar

L18

L2-L5

EXP

Algebraic

L19

L3-L5

EXP

Algebraic

L20

L4-L5

EXP

Algebraic

L21

L2-L4

EXP

Algebraic

CASE : 3 Basic parameter with Seismic loading :

Following parameters will be used for formulating the load cases,
U1 = Seismic loads also known as Uniform loads in terms of g in
North-South Directions.
U2 = Seismic loads also known as Uniform loads in terms of g in
East-West Directions.
U3 = Seismic loads also known as Uniform loads in terms of g in
Vertical Directions.
Note :
vertical load due to seismic is negligible and not included in the Load
case formation.

Load Cases:
Case No. Load Case
L1

WW+HP

Stress
Type
HYDRO

Combination
Type
Algebraic

L2

W+T1+P1

OPE

Algebraic

L3

W+T2+P2 (P1 can be used in this case) OPE

Algebraic

L4

W+T3+P3 (P1 can be used in this case) OPE

Algebraic

L5

W+P1

SUS

Algebraic

L6

W+T1+P1+U1

OPE

Algebraic

L7

W+T1+P1-U1

OPE

Algebraic

L8

W+T1+P1+U2

OPE

Algebraic

L9

W+T1+P1-U2

OPE

Algebraic

L10

L6-L2

OCC

Algebraic

L11

L7-L2

OCC

Algebraic

Case No.

Load Case

Stress Type

L12

L8-L2

OCC

Combination
Type
Algebraic

L13

L9-L2

OCC

Algebraic

L14

L5+L10

OCC

Scalar

L15

L5+L11

OCC

Scalar

L16

L5+L12

OCC

Scalar

L17

L5+L13

OCC

Scalar

L18

L2-L5

EXP

Algebraic

L19

L3-L5

EXP

Algebraic

L20

L4-L5

EXP

Algebraic

L21

L2-L4

EXP

Algebraic

CASE : 4 Basic parameter with wind & Seismic loading :

Following parameters will be used for formulating the load cases,
WIN1 = Wind Load in +X direction
WIN2 = Wind Load in X direction
WIN3 = Wind Load in +Z direction
WIN4 = Wind Load in Z direction
U1 = Seismic loads also known as Uniform loads in terms of g in
North-South Directions.
U2 = Seismic loads also known as Uniform loads in terms of g in
East-West Directions.
U3 = Seismic loads also known as Uniform loads in terms of g in
Vertical Directions.

Load Cases:
Case No. Load Case
L1

WW+HP

Stress
Type
HYDRO

Combination
Type
Algebraic

L2

W+T1+P1

OPE

Algebraic

L3

W+T2+P2 (P1 can be used in this case) OPE

Algebraic

L4

W+T3+P3 (P1 can be used in this case) OPE

Algebraic

L5

W+P1

SUS

Algebraic

L6

W+T1+P1+WIN1

OPE

Algebraic

L7

W+T1+P1+WIN2

OPE

Algebraic

L8

W+T1+P1+WIN3

OPE

Algebraic

L9

W+T1+P1+WIN4

OPE

Algebraic

L10

W+T1+P1+U1

OPE

Algebraic

L11

W+T1+P1-U1

OPE

Algebraic

Case No.

Load Case

Stress Type

L12

W+T1+P1+U2

OPE

Combination
Type
Algebraic

L13

W+T1+P1-U2

OPE

Algebraic

L14

L6-L2

OCC

Algebraic

L15

L7-L2

OCC

Algebraic

L16

L8-L2

OCC

Algebraic

L17

L9-L2

OCC

Algebraic

L18

L10-L2

OCC

Algebraic

L19

L11-L2

OCC

Algebraic

L20

L12-L2

OCC

Algebraic

L21

L13-L2

OCC

Algebraic

Case No.

Load Case

Stress Type

L22

L5+L14

OCC

Combination
Type
Scalar

L23

L5+L15

OCC

Scalar

L24

L5+L16

OCC

Scalar

L25

L5+L17

OCC

Scalar

L26

L5+L18

OCC

Scalar

L27

L5+L19

OCC

Scalar

L28

L5+L20

OCC

Scalar

L29

L5+L21

OCC

Scalar

L30

L2-L5

EXP

Algebraic

L31

L3-L5

EXP

Algebraic

L32

L4-L5

EXP

Algebraic

L33

L2-L4

EXP

Algebraic

Report Generation of analysis:

1.

Sustained stress summery 100 % (If possible preferably limit to

80% taking constraints and future revision allowance)

2. Sustained Displacement -5 mm ( In Vertical)

2 mm ( In Horizontal)
3. Hydro test stress summery 100 % (If possible preferably limit to
80% taking constraints and future revision allowance)
4. Sustained Displacement 5 mm ( In Vertical)
2 mm ( In Horizontal)

5.

Expansion stress summery 100 % (If possible preferably limit to

80% taking constraints and future revision allowance)

6. Occasional stress summery 100 %

7.

Restrained summary Extended = (SUS)+(HYDRO)+(OPE)+

(WIND/OCC)

8. Operational Displacement 25 mm ( loops up to 100 to 120 mm )

9. Occasional Displacement 25 mm
10. Normally a line should not lift in expansion condition at any
support

Thank You..