Examples Applying Fea Results With Caesar II Models Webinar PDF

Paulin Research Group - FEATools TM
“FEATools with CAESAR II – a better analysis”
Presenter: Tony Paulin, P.E.
Copyright © 2013 - Paulin Research Group. All rights reserved.

No portion of this document may be reproduced or retransmitted without the express written permission of Paulin Research Group.
What FEATools “is” and what FEATools “is not”
• FEATools is an automated CAESAR II model modifier that can solve stress and rotating
equipment problems automatically with almost no input from the user.
• FEATools is not a solution for every problem. There are certain piping model
geometries as pointed out in WRC 329 that respond very favorably to the use of more
applicable flexibility and stress intensification factor data. FEATools is designed for
those problems. One objective of this webinar is to help the user identify these types
of problems.
• FEATools is a proprietary suite of programs designed for use with CAESAR II using
approaches identified in 1987 with WRC 329, implemented in ASME Section III, and
verified in the PRG lab using experimental methods updated from B31.J and WRC 346.
• FEATools provides a standard application of approaches identified by WRC, EPRI, ASME

Section VIII Div 2 Part 5 and PRG. The unique quality of FEATools is that the process of
application is automated by a company that has been doing the same thing since
1990, and the FEATools software development team is headed by the same person
that was the original author of the CAESAR II pipe stress program.

What FEATools “is” and what FEATools “is not”
• FEATools is an automated CAESAR II model modifier that can solve stress and rotating equipment
problems automatically with almost no input from the user.
• FEATools is a collection of stand alone finite element programs.
• FEATools is a SIF and stress evaluator.

What FEATools “is” and what FEATools “is not” Summary:
Model
Modifier
Stand-alone
FEA
SIF & Stress

Allowables
and Failure
What FEATools “is” and what FEATools “is not” Summary:
FEATools Main Menu

There are a number of situations where the SIFs from the Code
can be nonconservative and where the k-factors in the Code
should be improved.

Short Summary:
• When k-factors are large and the system is stiff the affect on the calculated result
can be large, where “large” can be a maximum of around 10. Generally the result is
smaller and between 20 and 200%. Small errors are more important when there is
rotating equipment in the model, large errors are also important when changes in
the pipe routing or supporting have an economic impact on the project.
• When the d/D ratio is between 0.5 and 1 as stated in Note 11 of B31.3 Appendix D
the stresses may be half of what they should be.
• When the d/D ratio is less than 0.5 the i-factors in the run pipe can be highly
overestimated by more than 2 as the D/T ratio gets larger.
• For B31.3 the torsional i-factor is not 1 and increases as the D/T ratio gets larger.

Method Checks
When D/T > 35 check the i-factors and k-factors for the system using the FEATools PRGiK
spreadsheet.
When the system is classified as “severe cyclic” check i-factors and k-factors.
Check the following configurations for most systems:
PRGiK a)Largest d/D for the largest D/T.

b)Largest (d/D)(D/T)0.5.
c)Largest D/T when d/D ~ 0.5
d)Largest D/T when d/D < 0.25
e)Largest D/t when d/D ~ 1
Compare the B31 i- and k-factors to ST-LLC 07-02 i- and k-factors. Where they
agree then perform the stress as usual. Where they do not agree then take
extra precaution.
Decide where the system is looped and/or stiff. If the stresses or the loads are high and a
C2- problem due to stress or rotating equipment then run the FEATools C2-Translator to see if
Translator the real answers are better.

Severe Cyclic Conditions

f = 1 corresponds to 7000 cycles
f = 1.2 corresponds to 3125 cycles
f = 2.2 corresponds to 150 cycles
The test data suggests that “f”
could get as high as 2.2 at 150 cycles
and still provide an accurate fatigue
evaluation.
Severe Cyclic Conditions:
Markl: ireal (M/Z) > 0.4 x 490 N -0.2 ;ksi, range
PVP 2008-61871: ireal (M/Z) > 0.4 x 1894 N – 0.335` ;ksi, range
PVP 2008-61871: ireal (M/Z) > 0.4 x 1894 N – 0.335 ;ksi, range
Notes:
1) 0.4 = 0.8 x 0.5. At 7000 cycles, the allowable stress is approximately

equal to 1/2 of the mean stress to failure. The curves for the mean
stress to failure from Markl and Hinnant (PVP2008-61871) are known
as 490N-0.2 and 1874N-0.335 respectively.
2) ireal is the actual stress intensification factor. When it is known that

the stress intensification factor used in the pipe stress analysis is too
low, it must be increased by the difference, or multiplied by the
largest 07-02 and B31 i-factor ratio.
3) The percentage of the allowable used is based on the allowable from

a typical pipe stress program that is based on 6 x N-0.2 [ 1.25(Sc+Sh)]

PVP 2008-61871: ireal (M/Z) > 0.4 x 1894 N – 0.335` ;ksi, range
Branches are included at nodes 20 and 120 as shown in figure above.

D/T = (30-0.5)/0.5 = 59 d/D << 0.5
The D/T ratio is greater than 35 – and so we want to take a look in the
PRGiK spreadsheet to see if there’s any difference between more
applicable data and the Code values that will be used.
The d/D ratio is << 0.5 and so we know that run side i-factors are going
to be very overconservative – and so we want to take a look at this too.

Do = 30”
T = 0.5”
do = 2.375”
t = 0.218”

The PRGiK spreadsheet tells us that
the Code i-factors are many times
too high for run moments. We
expect a problem.

26” 40”
Temperature = 250F Pressure = 9psig

Service: Warm gas from burner sample burner discharge to precipitator
120
Piping Branches: 26x40 (All pipe 0.5” wall)

40x40
Copyright © 2013 - Paulin Research Group. All rights reserved. 20
Stress Increase Estimate = 12.3/5.69 x 2.95/5.3 = 1.2
Copyright © 2013 - Paulin Research Group. All rights reserved. 27
WRC 107 Table 3, p.7
Perform Load Analysis on

the Spherical Head at the
bottom of the Separator
OD = 48 x 0.75”
Branch = 14 x 0.375”
Loads on 14” Branch Pipe
Forces in lbs. Moments in Ft.Lbs.
Case Pres FX FY FZ MX MY MZ
W 0 0 1034 403 13 0 143
W+P 9 0 1034 407 14 0 324
W+P+T1 9 14 309 -43 28472 134 -25040
W+P+T2 9 -33 108 -55 -22075 -89 27433

WRC 329 Fig. 15 Example Piping Model
Without considering the branch

connection flexibility of the 12x30”
fabricated tee at point 15 the out-of-
plane (Z) bending moment at point 15
is 372,000 in.lb. Including the branch
connection flexibility reduces the
bending moment to 41,832 in.lb., a
reduction of 8.8.

Example No. 5 Heater Piping
Example No. 5 Heater Piping

Conclusions:
1)There are three very nice, relatively independent tools available in FEATools. There is a
CAESAR II file converter that incorporates more applicable i and k-factors. There is an i-K
spreadsheet that lets us evaluate more applicable data that may be needed for our pipe
stress analysis, and there are several stand alone finite element programs that are very
easy to use for typical configurations.
2)The WRC 329 recommendations for the B31 Piping Codes an be checked easily to see if
they apply to our system using the PRGiK spreadsheet.
3)Severe cyclic service can be interpreted to mean a system where the maximum stress
is greater than 0.8x0.5 = 40% of mean failure stress at the given number of cycles. A
chart with the equations for use is given in the slides so that the user can define
equivalent severe cyclic service.
4)Where there are multiple operating cases, the load history processor should be used.
5)It is easy to convert one CAESAR II model into a more applicable CAESAR II model and
see if an improvement in the loads or stresses results. In the examples we went through,
there were substantial changes both due to more applicable (corrected) k-factors and i-
factors.
Through the course of these webinars we hope to continue showing
practical examples where more accurate analysis approaches can
save time and money while providing a uniform, Code intended
safety.
Thank you for your time.
T. Paulin


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Paulin Research Group - FEATools TM

“FEATools with CAESAR II – a better analysis”

Presenter: Tony Paulin, P.E.

Copyright © 2013 - Paulin Research Group. All rights reserved.

• FEATools provides a standard application of approaches identified by WRC, EPRI, ASME

Copyright © 2013 - Paulin Research Group. All rights reserved.

• FEATools is a collection of stand alone finite element programs.

• FEATools is a SIF and stress evaluator.

Copyright © 2013 - Paulin Research Group. All rights reserved.

SIF & Stress

FEATools Main Menu

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Check the following configurations for most systems:

PRGiK a)Largest d/D for the largest D/T.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

1) 0.4 = 0.8 x 0.5. At 7000 cycles, the allowable stress is approximately

2) ireal is the actual stress intensification factor. When it is known that

3) The percentage of the allowable used is based on the allowable from

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Temperature = 250F Pressure = 9psig

Piping Branches: 26x40 (All pipe 0.5” wall)

Perform Load Analysis on

Copyright © 2013 - Paulin Research Group. All rights reserved.

Without considering the branch

Copyright © 2013 - Paulin Research Group. All rights reserved.

Copyright © 2013 - Paulin Research Group. All rights reserved.

Thank you for your time.

Copyright © 2013 - Paulin Research Group. All rights reserved.

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