Quick executive summary
● Applicable code: Primary design code is ASME B31.3 (process piping) — follow project
precedence rules (legal → datasheets → specs → codes).
● Analysis tool: Approved program is CAESAR II (Latest, v14 recommended); use
mm.fil (mm units) or project-specific unit file. Include T, P, weight, insulation in runs.
● Which lines to analyze: All stress-critical lines (size, temperature, service, rotating
equipment, PSV lines, expansion joints, cryogenic, HDPE, molten salt — see
thresholds). Prepare a Critical Line List.
● Main load cases to model: Hydro test, Sustained, Operating (normal & design temps),
Thermal expansion, and Occasional (wind, seismic, snow, PSV discharge, surge). Use
prescribed combinations & acceptance criteria (Sh, Sa, Sy).
● Supports & hangers: Spring hangers allowed (variable/constant). Limits for
pedestal/hanger movement, friction coefficients, and spring selection rules are defined.
Detailed salient points (by topic)
Codes, standards & precedence
● Primary: ASME B31.3; other referenced: ASME B31.5, B16.x, BPVC sections, ASTM,
API standards, MSS, AWS, EJMA, ENs as applicable. Follow project document
precedence (laws → datasheets → specs → referenced codes).
Which piping must be analyzed (stress-critical selection)
● Automatic analysis required for:
○ NPS ≥ 14” (all)
○ 2.5” ≤ NPS < 14”: depends on temperature/material — check table in document.
○ All rotating equipment connections (compressors, turbines, pumps, air coolers).
○ Expansion joints (all).
○ PSV lines (closed-circuit PSV & open-to-atmosphere > 2”).
○ Cryogenic lines (T ≤ −50°C).
○ HDPE (≥2”) and molten salt systems (all).
● Non-critical small lines may be handled by good engineering practice; but create & agree
Critical Line List early.
Design loads to include (minimum)
● Design/Operating/Test pressures, dead weight (normal & hydro), thermal expansion,
wind, seismic (site-dependent), snow, fluid transients (water hammer, surge), PSV
reaction, soil surcharge (UG), external displacements, installation temps.
Operation modes & load cases
● Typical set: Hydraulic test, Sustained, Normal operating (various pump
combinations), Design temp & pressure, Occasional (wind, earthquake), and other
operational permutations (bypasses, pumps on/off). Include friction where relevant,
especially near pumps/turbines.
Load combinations & acceptance (key formulas)
● Sustained: P + W → ≤ Sh (Sh = allowable operating stress).
● Occasional (wind): P + W + WIN → ≤ 1.2·Sh.
● Occasional (snow): P + W + SNOW → ≤ 1.33·Sh.
● Thermal expansion: TE → ≤ Sa (Sa = f(1.25Sc + 1.25Sh − SL), f = fatigue reduction
factor per B31.3).
● Testing (hydro): HP + WW → < 0.9·Sy (Sy = yield strength).
● Use the document’s CAESAR II load-case table for building combinations / SRSS where
required.
CAESAR II & modeling rules
● Approved tool: CAESAR II (latest). Use project unit file or mm.fil default. Always include
temperature, pressure, weight and insulation.
● Bourdon effect: Consider for translations and for flange classes 900# & above.
● Extend model to first fixed point at tie-ins or to two direction changes if no fixed point.
Buried metallic piping: model up to virtual anchor. Equipment modeled as rigid elements
unless vendor gives nozzle displacements (use WRC-297/537 for nozzle flexibility).
Pressure relief valve (PRV) reactions & surge
● PRV reaction forces: calculate for open & closed systems per API RP 520 Part II.
Dynamic Loading Factor (DLF) = 2 for reaction forces (thermal relief valves excluded).
Surge forces should be provided by Process/Simulation and screened as per Energy
Institute guideline.
Supports, spring hangers & friction
● Spring hangers: Variable and constant types allowed. Pedestal (“F” type) horizontal
displacement limited ±6 mm (±15 mm if sliding assembly used). Hanging support
horizontal deflection limited ±4°.
● Variable spring hanger load variation limits: compressors/turbines 6%, pumps 15%,
static equipment 25%. Use constant hangers when vertical movement or load variation
exceed limits or for critical high-temperature lines.
● Friction coefficients (static) to use: CS-CS = 0.3, CS-concrete = 0.45, CS-PTFE = 0.1,
SS-SS = 0.1. Include friction for vertical supports and near sensitive nozzles and long
runs.
Flange & nozzle checks
● Flange joints: ensure flange loads ≤ established values. Evaluate critical flange leakage
using ASME BPVC Section VIII Appendix 2 equivalent pressure or ASME VIII-2 or
ASME III NC-3658.
● Evaluate flanges for main equipment when T > 200°C and P > 30 bar(g) (or
case-by-case judgment).
● Nozzle allowable loads: use vendor or code values (API values for pumps/compressors):
e.g., API 610 nozzle limits (x2 factor for non-API pumps as guideline), compressors use
3× API 617 guidance. For large nozzle sizes / high classes consult rotating/static
equipment engineers.
Pipe rack, expansion loops & rack loading
● Expansion loops: allowed thermal movement guidance — inside loop 150–200 mm,
outside turns 75–100 mm (typical). Determine loop count based on required movement;
avoid a single huge leg if it creates anchor loads — nest loops if possible.
● Rack loading: provide initial conservative loads early, review at 30% and 60% model
reviews with updated concentrated and distributed loads. Preliminary UDL guidelines:
1.5 kPa for piping/product/insulation; for heavy platform areas provide higher UDL (≥7.5
kPa for lines/platforms >20"). Mark point loads for large lines (≥12"). Include PSV
reactions where applicable.
Wind / Snow / Seismic
● Wind: use EN 1991-1-4; site base wind Vb = 23 m/s, Terrain Category II. Peak velocity
pressure vs height table provided in doc — apply wind in +X, −X, +Y, −Y and
combinations (SRSS).
● Snow: Ws = ½·Do·So where So = 0.35 kN/m².
● Seismic: site return period indicates ag < 0.02 → seismic analysis not necessary per
site data (verify site data early).
Two-phase flow & vibration
● Two-phase lines: provide hold-downs, guides, axial stops; perform modal analysis and
ensure natural frequency > 4 Hz. Use friction stiffness factor 25 for dynamic friction
modeling. Consider acoustic/flow-induced vibration and water-hammer.
Hydrotest, sag & installation temps
● Hydrotest acceptance: HP + WW < 0.9·Sy.
● Pipe sag limit: sustained & hydro test sag ≤ 15 mm; add supports if exceeded.
Temporary supports allowed only for hydrotest.
● Installation temperatures: Hot install = 23.4°C, Cold install = −3.5°C (project ambient
references use 10°C ambient for calculations).
Fatigue
● Consider pressure & thermal cycles. If thermal cycles > 7000, do a fatigue analysis per
B31.3. The fatigue reduction factor f must be determined case-by-case.
Buried piping & tie-ins
● Buried metallic piping: model up to virtual anchor. For tie-ins extend model to first fixed
point or two changes of direction. Module-to-module connections: consider flange or
golden joint per project requirement.
Rigid element data & weights
● Use Pipe-Data-Pro or equivalent for rigid weights if not available in CAESAR library. Bolt
weight rules and guidance listed — consider bolt weights for flanges in sizing rules and
consider actuated valve weight = 1.5× manual valve for preliminary analysis if vendor
data missing.
Expansion joints / bellows / special hardware
● Do not use expansion joints, bellows, snubbers, struts etc. without management
approval. Treat these as special items and justify via vendor/management approvals.
Cryogenic piping note
● Cryogenic piping may be analyzed with ASME B31.3. Material properties change at low
temps: strength typically increases, modulus may increase, expansion coefficient
decreases — account for property changes in model.
Required deliverables / documentation (stress report)
The stress analysis report should at minimum include:
● Input data, assumptions, recommendations & conclusions
● Extract of process critical line list & PEFS (systems)
● Equipment drawings & datasheets
● Piping classes & isometrics (if applicable)
● Spring hanger datasheets, load case reports, stress & restraint summaries
● Anchor-free (WNC) displacement report when applicable
● A prepared checklist for analysis input & output verification.
Practical checklist — what you must
collect before starting
1. P&IDs & Line list (with line service, insulation, classes).
2. Process data: max/min/operating temps & pressures, surge/water-hammer forces from
Process.
3. Hydrotest pressure and installation temperatures.
4. Equipment vendor data: nozzle allowable loads, thermal growth/nozzle displacements,
equipment weights.
5. Valve & fitting weights (actuated valve vendor data or 1.5× manual valve for
preliminary).
6. Insulation spec & insulation density.
7. Support standard & spring hanger data (vendor catalogs).
8. Soil settlement estimates, rack GA and platform levels.
9. Site data: ambient temp, wind table, seismic return period.
10.Critical Line List (prepare & agree with lead/process).
11.CAESAR II unit file (mm.fil) and project setup details.
Red flags / common pitfalls to avoid
● Starting analysis without vendor nozzle loads (causes rework).
● Failing to model equipment thermal growth (overstressed nozzles).
● Ignoring friction near pumps/turbines — anchor loads will be wrong.
● Not performing anchor-free (WNC) checks for rotating equipment (must allow small
axial/lateral displacement).
● Allowing large single expansion legs instead of splitting loops (huge anchor loads).
● Using default spring hanger selection without checking load variation % for that
equipment.
● Forgetting DLF=2 for PSV reaction forces.
Quick action plan I recommend (next
24–48 hrs)
1. Assemble the Critical Line List and P&IDs; mark obvious critical lines (rotating eqpt,
large diameters, high T, PSV, cryo).
2. Request vendor nozzle loads & thermal growth for all rotating & major static
equipment.
3. Create CAESAR II project unit file (mm.fil) and set up one representative line model to
validate assumptions (weights, insulation, hanger setup).
4. Prepare load-case matrix in CAESAR following the doc’s table and run Sustained /
Expansion / Hydro / Occasional combinations.
If you want I can next:
● Convert this into a one-page checklist/PDF you can hand to your lead; or
● Translate the whole summary to Tamil (since you prefer technical Tamil), or
● Start a template CAESAR II setup checklist (unit file checks, rigid elements, spring
data, load case naming) that you can use to build the first model.
