Piping to Nozzle to Vessel

Piping Engineer vs. Vessel Fabricator

Did you check the nozzle for loads
Alright.., Give me actual loads
My Nozzle is good for Pressure
But, the analysis is not finished yet
Ok, give me Maximum Loads your nozzle can withstand
What !, there are infinite combinations...
Saga of Nozzle loads
What came first,
Or
Some Ideas for resolution
Use standard Nozzle Loads
Provides a standard level of strength
Some Ideas for resolution
Get a Maximum Nozzle load set
Indicate if you want a bigger Mx, My etc..
Resolutions .
Model Nozzle flexibilities in Piping model
Ask for the loads in categories SUS, EXP,
OCC
Thermal Expansion Self-limiting, so higher
allowable
Occasional 20% increase in allowable
Stresses near Nozzles
2. Some methods employed:
Welding Research Council Bulletin (WRC) 107
Local Stress Analysis
Welding Research Council Bulletin (WRC) 297
PD5500 (British code), Annex- G
Finite Element Analysis (FEA)
Welding Research Council Bulletin (WRC) 368
WRC107
1965, updated in 1979, Prof. Bijlaard work
Provides stress in Cylinder and Spheres
Gives verifiable solution, used for a long time.
Based on Un-penetratedshell
Gives stresses in header only
Consists of charts and fill in tables.
Radial Force P
Longitudinal Force VL
VL
Circumferential Force VC
VC
MC
P
Circumferential Moment MC
Longitudinal Moment ML
ML
Torsional Moment MT
WRC 107 CONVENTION
MT
AU
DU
BU
CU
AL
BL
CL DL
Lots of charts to look up
Then fill in tables

2
x, )
1 +2)/2

Max Shear
Stress
Stress Intensity
o1
ox oy + ox oy
, )
2
4t
2
+ +
2
:=
o2
ox oy + ox oy
, )
2
4t
2
+
2
:=
x
y

1 - 2
Then Use, Mohr
Circle
Stress Combinations
Next, Combine stresses in categories
General Primary Membrane (Pm)
Local Primary Membrane (Pl)
Secondary Stresses (Q)
Compare to allowables
Primary Stresses
load-controlled pressure, weight
Not self-limiting
Tighter limits (1.5*S)
Secondary Stresses
Strain-controlled thermal Exp., bending at
gross discontinuities
Self-limiting stress can reduce after local
yielding.
Higher allowable (approx 3*Savg)
Some limitations of WRC107
Re-pad not considered
Assumes a 90(radial nozzle)
Spherical Shells
d
i
/D
i
1/3 but less if Dm/T between 20-55
U 2.2 (U =r
o
/ ((R
m
T)0.5, for nozzle)
0.25 t /T 10
5 r
m
/t 50
Cylindrical Shells:
d/D for cylinders or <0.6 with significant warnings
D/T 600
L/D 1.5
C1 /C2 4
WRC 297
Based a different, thin shell theory (Prof.
Steele)
For cylindrical nozzles on cylinders
Extends the range of WRC 107 (d/D s 0.5)
Gives stresses both in header and branch
Also provides Nozzle Flexibilities
A
B
D
A
B
D C
Vessel Orientation +y direction
Nozzle Orientation +x direction (toward vessel)
B to A Convention In the direction of the vessel
x
y
z
GLOBAL COORDINTES
x
y
z
A
B
D
A
B
D C
Fx force P RADIALLY INWARD
Fy force VL FROM B -> A
Fz force -VC FROM C - > D
Mx moment -MT TORSIONAL
My moment -MC CIRCUMFERNETIAL
Mz moment -ML LONGITUDINAL
P
VL
-VC
-MT
-ML
-MC
A WAY TO REMEMBER TO DIRECTIONS:
P IS RADIALLY TOWARD THE VESSEL
VL IS FROM B -> A
VC IS FROM D-> C
MT IS RADIALLY OUTWARD
MC IS FROM D->C
ML IS FROM B -> A
Example Geometry
1. Shl: 144 in. ID, 1.5 in. thk, 240 in Len., SA-516 70
2. Noz: 24 in. ID, 1 in. thk., 10 in Len, SA-516 70.
3. Internal Pressure: 200 psi
4. Loads: P = 5400 lbs, VL = 2100 lbs, ML = 3500 ft-lbs.
5. Radial Nozzle in the shell center.
WRC Parameters for this
example:
1. d/D: 0.167 ( <0.3 )
2. L/D: 1.67 ( >1.5 )
3. D/T: 96 ( <= 600)
4. d/T: 16 ( >=5 )
5. d/t: 24 ( >20 )
Within ranges of 107 and 297.
PD5500 Convention
Pressure Thrust
Force on the vessel-nozzle junction due to
pressure
Pressure Thrust
Nozzle with a blind-
Typically, a more flexible system, more
thrust load on nozzle.
Entire thrust load
Pressure Thrust and WRC107
Pressure Thrust and WRC 107
Use WRC 368 or FEA and watch for WRC 107 limits
Missing data, Curve
exceeded
WRC Bulletin 368: Stresses due to Pressure and
Pressure Thrust
Max. Stress Intensities for nozzle-cylinder junction due to
Internal Pressure.
Derived from the FEA data.
Loadings include Internal Pressure +Pressure Thrust
More Accurate way of modeling Pressure Thrust (PT)
But, does not combine well with stress due external loads
Use as a tool for pressure only case
FEA interface
1. FEA Interface to NozzlePro program from
Paulin Research Group (www.paulin.com).
2. Reuse input from 107, blends in with
CodeCalc/PVElite.
3. Additional capabilities- geometric, analysis.
WRC vs. FEA
Accurate modeling repad, hillside/Y-angle
nozzles
No limitation of d/D, etc.
Accurately combine Pressure and stresses due to
external loads.
Accuracy is not limited on the geometry
Results and Comparison
1. The ASME check: Design Pressure 200 psi
Method MAWP (psi)
Area of Replacement
(UG-37)
232
CodeCase 2168 306
WRC 368:
Shell
Nozzle
252
233
2. 107 v/s 297 v/s PD5500: Max. Stress Intensity.
* Stress intensity in ksi
Method Au Bl Cu Dl
107 8.02 9.86 8.12 10.56
297 8.05 9.98 7.71 11.16
PD5500 26.1 28.3 27.6 28.9
2.b Stresses from PD5500:
Method Pressure stress
107 9.5
PD5500 27.7
27.7/(Pressure Stress SIF) = 27.7/2.864 = 9.7 ksi.
3. 107 v/s 297 v/s PD5500 v/s FEA:
* Stress intensity in ksi
Method Pm +Pl stress Allow
107 9.52 30
107 +PT 15.58 30
107 +PSI 31.03 30
PD5500 27.75 29.6
FEA 20.53 30
4. Location of highest stress ?
Method Location
107
Shell B inner (PM +PL)
C, D inner (PM+PL+Q)
297 Nozzle C, D inner !
368 Nozzle
PD5500 Shell Q1, Q4 inner
FEA
Shell (PM +PL),
Nozzle (PM+PL+Q) !
Conclusions
1. WRC 107/297 are good tools when used within their
limits.( e.g when d/D >0.33.)
2. It provides good first step.
3. Be aware of its limitations, Re. pads, hillside nozzles, inside
projection use FEA for accurate stress pattern
4. Always check Nozzle per ASME code first.
5. Stresses in Nozzle can be higher than Shell stresses:- WRC
297, FEA.
6. Input loads in categories (Sustained, Expansion..) to take full
advantage of the code allowables.
References
1. WRC bulletins 107, 297 & 368. Pressure Vessel
Research Council
www.forengineers.org/pvrc/index.htm.
2. Mechanical Engineering Newsletter articles- J uly
2001, J une 2000 and J une 1997. Available at
www.coade.com.