Pipe Stress Analysis Using
CAESAR II
Piping System Analysis
Why do we do it? When & Why Stress Analysis
Analysis.doc
doc
What do we do?
How do we model the piping system?
How do we document the work?
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
1
Pitfalls of
Piping Flexibility Analysis
Just about any set of numbers can run
through a piping program (GIGO)
Elements used in piping programs have
their limitations
A good analysis addresses these
limitations
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
3D Beam Element
A purely mathematical model
All behavior is described by end
displacements using F=Kx
Basic parameters define stiffness and load
(K and F, respectively)
Diameter, wall thickness,
Diameter thickness and length
Elastic modulus, Poisson’s ratio
Expansion coefficient, density
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
2
3D Beam Element
Behavior is
dominated by
bending
Efficient for most
analyses
Sufficient for
system analysis
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
3D Beam Element
What’s missing?
g
No local effects (shell distortion)
No second order effects
No large rotation
No clash
No accounting for large shear load
Where wall deflection occurs before
bending
As in a short fat cantilever (vs. a long
skinny cantilever)
Centerline support
No shell/wall
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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3D Beam Example
Si l cantilever
Simple il bending:
b di
L P
δ
L3
δ = P⋅
3⋅ E ⋅ I
(x = F )
K
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
How Do We Represent
Stress?
4
Evaluating Stress at a Point
Local coordinate system
Longitudinal
Hoop
Radial
End loads and pressure
through a free body
diagram
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Stress Element
Longitudinal stress
F/A, PD/4t, M/Z (max. on outside surface)
Hoop stress
PD/2t
Radial stress
0 (on outside surface)
Shear stress
T/2Z, (V=0 on outside surface)
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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From 3D to 2D
With no radial stress the cube can be
reduced to a plane.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Equilibrium
Stress times unit area = force
Any new face must maintain equilibrium
New face will have a normal and shear
stress component
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Mohr’s Circle
Calculation of these new face stresses are
symbolized through Mohr’s circle
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Named Stresses (Definitions)
Principal stress – normal stress on the
face where no shear stress exists
Maximum shear stress – face upon which
shear stress is maximum
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Mohr’s Circle
Representation
Principal Stresses:
S1, S2, S3
Maximum Shear Stress:
τmax
so....
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Any complex stress on an element can be
represented by the principal stresses (S1,
S2, S3) and/or the maximum shearing
stress (τmax)
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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How Do We Measure
Failure?
Modes of Pipe Failure
Burst – due to pressure
Collapse – due to overload
Corrosion – a material consideration
Fatigue – cyclic loading
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Other Failure Concerns
Too much deflection (clash)
Overloaded pump or flange
(bearing/coupling failure or leak)
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
How Do We Measure Failure?
Maximum p
principal
p stress – S1 ((Rankine).
)
Principal stress alone causes failure of the element.
Wall thickness calculations due to pressure alone.
Maximum shearing stress – τmax (Tresca).
Shear, not direct stress causes failure.
Common stress calculation in piping.
M i
Maximum distortion
di t ti energy – wd (von
( Mises).
Mi )
Total distortion of the element causes failure.
Octahedral shearing stress (τGmax) is another measure
of the energy used to distort the element. This is
known as equivalent stress.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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How Do We Measure Failure?
These are just three
Others include maximum strain and
maximum total energy
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Which Measure Do We Use?
Energy
e gy oof d
distortion
sto t o iss tthe
e most
ost accu
accurate
ate
prediction of failure but maximum shearing
stress is close and conservative.
Piping codes often utilize their own mix (through
the term “stress intensity”).
CAESAR II can print either Tresca or von Mises
stress in the “132 column” stress report.
Our (code) focus is maximum shearing stress.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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From Lab to Field
How Do We Compare
F il
Failures?
?
Material Characteristics
Lab produces stress-strain
stress strain characteristics
for our alloy
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Material Characteristics
Direct (axial) load on a test specimen to
yield and ultimate failure
Gives E, Sy, Sult
These terms vary with temperature
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Lab Failure
If failure occurs at
yield, the appropriate
stress is calculated
using the yield load
Sy = Py/a
And this is our limit
τmax ≤ Sy/2
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Field Failure
If stress of interest (S1, τmax , τoct) on the
field element is greater than the lab
element, failure is predicted
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Piping Code Simplification
Us g tthe
Using e maximum
a u sshear
ea cacalculation…
cu at o
τmax is the radius of Mohr’s circle.
τmax = (S1-S3)/2.
So, (S1-S3)/2≤ Sy/2.
Or (S1-S3) ≤ Sy
Piping codes define (S1-S3) as stress intensity.
Stress intensity must be below the material
yield.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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More Simple?
Hoopp stress (S
( H) is positive
p and below yyield due
to wall thickness requirements (design by rule).
Radial stress is zero, assume this is S3.
Longitudinal stress (SL), assumed positive, must
be checked only if it exceeds hoop stress, then
S1=f(SL,τ) and (S1-S3)= f(SL,τ).
S with
So, ith h
hoop stress
t accounted
t d with
ith wallll
thickness, you need only evaluate longitudinal
and shear stresses and compare the results with
the material yield, Sy.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
If SL is negative, then SL becomes S3 and
SH is S1. This produces a greater stress
intensity of (SH – SL). This is a concern
for “restrained pipe” most commonly
found in buried piping systems.
Oh
Otherwise, as long
l as longitudinal
l d l stress is
below yield, the pipe material will not fail.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Or So You Might Think…
Other Failures Do Occur
Through the wall cracks on components
Through-the-wall
subject to thermal strain
Not immediate
Low cycle and high cycle fatigue
Rupture at elevated temperatures (creep)
Again, over time
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Effects of thermal strain were investigated
and addressed by A.R.C. Markl et. al. in
the late 40’s and into the 50’s.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Yield Is Not the Only Concern
Yield is a “primary”
primary concern for force-
force
based loads which lead to collapse.
But other, non-collapse loads exist.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Non-collapse Loads?
Deadweight loads must satisfy equilibrium
(F in F=Kx is independent) or collapse.
Displacement-based loads such as thermal
strain can satisfy static equilibrium
through deformation and even local
structural yielding.
Here, x in F=Kx is independent but
material yield will limit K and therefore F.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Are There Strain Limits?
Going cold to hot may produce yield in
the hot state but there will also be a
residual stress in the system when it
returns to its cold condition
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Are There Strain Limits?
But what if this residual cold stress
exceeds its cold yield limit?
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Are There Strain Limits?
Yield will occur at both ends of every
thermal cycle
This is low cycle fatigue
Failure will occur in only a few cycles
(Try this with a paper clip.)
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Shakedown and Its Limits
Initial yield is acceptable.
This is known as shakedown.
But to avoid low cycle fatigue failure, the
overall change in stress – installed to
operating – must be less than the sum of
the hot yield stress and the cold yield
stress…two times yield!
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Shakedown and Its Limits
Yielding is acceptable; The pipe “shakes
shakes
down” any additional strain.
Expansion stress range ≤ (Syc+Syh).
The code equations limit this stress to
(1.25Sc+1.25Sh).
The stress at any one state (hot or cold)
cannot measure this fatigue stress range.
(One limit for S is based on Sy: S=2/3 Sy, so Sy=1.5S)
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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But We’re Not Done…
Yet other systems have been in service,
cycling for many years, only to fail later in
life.
This is evidence of high cycle fatigue.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Material Fatigue
Polished bar test specimens will fail
through fatigue under a cyclic stress
The higher the stress amplitude, the
fewer cycles to failure
Fig. 5-110.1, Design Fatigue
Curves from ASME VIII-2 App. 5 –
Mandatory Design Based on
Fatigue Analysis
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Piping Material Fatigue
This is reflected in the allowable stress by the
cyclic reduction factor – f.
Expansion stress Se ≤ f(1.25S
f(1 25Sc+1.25S
+1 25Sh).
)
To address ratcheting, the force-based stress
(SL) will reduce this acceptable stress amplitude.
Therefore, Se ≤ f(1.25Sc+1.25Sh-SL).
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Some Components Fail
“Sooner” Than Others
Failures occurred at pipe connections,
bends and intersections.
Markl’s work examined the cause of these
fatigue failures
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Bend Failure
Pipe bends ovalize
as they bend
This makes them
more flexible
And makes them
fail “sooner” than a
butt weld
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Component Fatigue
Markl tested various piping components
and plotted their stress and cycle count at
failure.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Stress Intensification
Rather than reduce the allowed stress for
the component in question, this SIF (or i)
increases the calculated stress.
Stress = Mi/Z.
S bw
i=
S el
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
In-Plane/Out-Plane
Process piping distinguished between in
in-
plane bending and out-plane bending
In-plane bending keeps the component in
its original plane
Out-plane bending pulls the component
out of its plane
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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In-Plane/Out-Plane
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Markl’s Work in Today’s Code
Markl extended his findings to several
pipe components and joints.
This work appears in Appendix D.
Pay attention to the notes.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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B31.1 Appendix D
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
B31.3 Appendix D
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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B31.3 SIF Example
B31.3 Sample
p SIF Calculations
Welding elbow or pipe bend Reinforced fabricated tee with pad or saddle
Input Input
Pipe OD : 10.75 10.75 10.75 10.75 Pipe OD : 10.75 10.75 10.75 10.75
Pipe wall : 0.365 0.365 0.365 0.365 Pipe wall : 0.365 0.365 0.365 0.365
Bend radius : 15 10 30 50 Pad thickness : 0 0.25 0.365 0.5
Intermediate Calculations Intermediate Calculations
Tbar = 0.365 0.365 0.365 0.365 Tbar = 0.365 0.365 0.365 0.365
R1 = 15 10 30 50 Tr = 0 0.25 0.365 0.5
r2 = 5.193 5.193 5.193 5.193 r2 = 5.193 5.193 5.193 5.193
h= 0.203 0.135 0.406 0.677 h= 0.070 0.147 0.194 0.259
Stress Intensification Factors Stress Intensification Factors
out-of-plane = 2.171 2.845 1.368 1.000 out-of-plane = 5.284 3.234 2.688 2.215
in-plane = 2.605 3.414 1.641 1.167 in-plane = 4.213 2.676 2.266 1.911
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
B31.1 SIF Example
B31.1 Sample
p SIF Calculations
Welding elbow or pipe bend Reinforced fabricated tee with pad or saddle
Input Input
Pipe OD : 10.75 10.75 10.75 10.75 Pipe OD : 10.75 10.75 10.75 10.75
Pipe wall : 0.365 0.365 0.365 0.365 Pipe wall : 0.365 0.365 0.365 0.365
Bend radius : 15 10 30 50 Branch OD : 4.5 4.5 4.5 4.5
Branch wall : 0.237 0.237 0.237 0.237
Branch OD at tee : 5
Pad thickness : 0 0.25 0.365 0.5
Intermediate Calculations Intermediate Calculations
tn = 0.365 0.365 0.365 0.365 tn or tnh = 0.365 0.365 0.365 0.365
R= 15 10 30 50 r or Rm = 5 193
5.193 5 193
5.193 5 193
5.193 5 193
5.193
r= 5.193 5.193 5.193 5.193 tnb = 0.237 0.237 0.237 0.237
rm = 2.132 2.132 2.132 2.132
rp = 2.250 2.500 2.250 2.250
h= 0.203 0.135 0.406 0.677 h= 0.070 0.147 0.194 0.259
Stress Intensification Factor Stress Intensification Factor
2.605 3.414 1.641 1.167 Header : 5.284 3.234 2.688 2.215
Branch : 3.471 3.124 3.471 3.471
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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To Summarize:
Unchanging loads (loads that do not vary with
system distortion – weight, pressure, spring
preloads, wind, relief thrust, etc.) must remain
below the material yield limit.
Strain-based loads (thermal growth of pipe,
pp
movement of supports) ) must remain below the
material fatigue limit
Several piping codes such as the transportation
codes also limit operating stress
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Piping Code
Implementation
What Are the Code Stress
E
Equations
ti and
d Th
Their
i Li
Limits?
it ?
28
A Review of the Basic
Concerns
Force-based
Force based loads are limited by yield
But also! Permanent or temporary?
These are “primary” loads and they produce
sustained and occasional stresses
Strain-based loads are limited by fatigue
These are “secondary” loads and they
produce expansion stresses
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Piping code equations:
Power Piping
B31.1, ASME III, B31.5, FBDR (, EN-13480?)
Most stringent limitations
Sample Equations
Sustained: Slp + (0.75i)Ma/Z < Sh
E
Expansion:
i iMc/Z
iM /Z < f(1.25Sc
f(1 25S + 1
1.25Sh
25Sh – Sustained)
S t i d)
Sustained + Occasional:
Slp + (0.75i)Ma/Z + (0.75i)Mb/Z < kSh
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Piping code equations:
Process Piping
B31.3, ISO 15649
Wider applications
Sample Equations
Let Sb = {sqrt[(iiMi)2+(ioMo)2]}/Z
p + Fax/A + Sb < Sh
Sustained: Slp
Expansion:
sqrt(Sb2 + 4St2) < f(1.25Sc + 1.25Sh – Sustained)
Sustained + Occasional:
Slp + (Fax/A + Sb)sus +(Fax/A+Sb)occ < kSh
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Piping code equations:
Transportation Piping
B31.4, B31.8, TD/12, Z662, DNV
Based of proof testing and yield limits
Addresses compression
Sample Equations
Let Sb = {sqrt[(iiMi)2+(ioMo)2]}/Z
Sustained: Slp + Sb < 0.75Sy
Expansion: sqrt(Sb2 + 4St2) < 0.72Sy
Operating: Sustained + Expansion < Sy
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Piping code equations:
FRP (GRP) Pipe
BS 7159, UKOOA (ISO14692)
Different materials different concerns
Equations evaluate the interaction of hoop
and axial stress
B d on d
Based design
i straini rather
h than
h stress
(but σ=εE)
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
CAESAR II – The Program
An Overview of
th D
the Design
i P
Procedure
d
31
Pipe Stress Analysis
and
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Design by Analysis
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Design by Analysis
The design cycle
Collect data (with assumptions)
Generate the model and load sets
Run the analysis
Check the assumptions
Diagnose any problems
Re-run with fixes
Document the analysis
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
The Design Cycle
Model
A system model, not a local model
Analyze
It’s just F = KX
Evaluate
Check the design limits
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Is It a Good Model?
Focus on stiffness
stiffness, boundary conditions and
loads.
Consider the stiffness method assumptions
(remember, it’s only an approximation).
Run a simple “sensitivity study” when you’re
unsure.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
A Sensitivity Study
Treat CAESAR II as a black box.
Examine the effects of a single input
modification.
Determine the sensitivity of the results to
that particular piece of data.
Examples: nozzle flexibility, friction,
support location, restraint stiffness.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Verifying Results
Equilibrium exists in static analyses.
Resultant loads equal applied loads.
Restraint loads for weight analysis sum to
total deadweight.
You can verify coordinates of key
positions.
ii
Check the plotted deflections.
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Design Limits
Pipe failure (stress)
Pipe Deflection
Equipment loads
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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Use a Sensitivity Study:
To improve the
values
To improve
p your
y
confidence
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Which Is Better –
a complex model
or a simple model?
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Summary
Basic stresses reviewed
Failure theories reviewed
SIFs introduced
Load case (stress) type introduced
Expansion case explained
Code equations summarized
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
Pipe Stress Analysis Using
CAESAR II
13-Feb-08 Introduction to CAESAR II and Pipe Stress Analysis
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