To first reply: I think he was referring to the weight difference of the load cases ([W+P1] vs. [WW+HP]), not the difference in weights due to pressure.
I agree with what was said right above. It depends on a few things:
- What type of fluid do you have? Is it heavier than water?
- If densities are the same for both test and operating fluid, then is the corrosion allowance big enough to cause these differences in weight? (what's the difference in force magnitudes?) Also, make sure you input your fluid density in the right units because standard is lbm/in^3 in Imperial.
- Does the line have insulation?
- Does the line have spring hangers/cans?
Or maybe even some mistakes could be the reason:
- Unlikely, but do you have displacements in your SUS case that you are not including in your HYD case? (even though this would make no sense since system is cold for both)
- Are you sure your Load Cases are set up correctly?
- Are you sure your Load Case Options are set up correctly? (check Springer Stiffness field for HYD case)
If it's none of this, then post the .CAESAR II file and let us take a look at it.