Seawater Electro-Chlorination Package — CAESAR II Stress Analysis

The challenge

The piping stress work for a seawater electro-chlorination package could not simply be updated — the earlier scope of incorporating comments into an existing model was replaced by a requirement to redo the stress analysis from scratch, with a new model, full documentation and code compliance for every stress-critical line.

Our scope

• New CAESAR II model of the complete system from the latest P&IDs, isometrics and line list
• Identification and routing of stress-critical lines
• Supports, guides, anchors and spring hangers
• Sustained, operating, occasional and thermal load cases
• Stress mark-ups on isometric drawings
• Stress analysis to ASME B31.3 (or client standards) with nozzle load evaluation
• Incorporation of client comments

Our approach

We rebuilt the analysis from first principles: every line was modelled with full piping data, routing and boundary conditions, and all four load-case families were applied before supports were optimised. Results were fed back onto the isometrics as clear stress mark-ups so the client’s piping team could act on them directly.

• Stress-critical lines identified up front from the latest P&IDs and line list
• Support scheme, including spring hangers where needed, set in the model
• Nozzle loads evaluated against equipment limits
• Client comments incorporated within the agreed review cycles

The outcome

The project was awarded and completed. The client received the editable CAESAR II model files, isometric drawings with stress mark-ups, and comprehensive stress reports — line-wise stress summaries, support loads and reactions, nozzle qualification results and displacement plots — demonstrating compliance with ASME B31.3.