INSTITUTE OF TECHNOLOGY, NIRMA UNIVERSITY, AHMEDABAD 382 481, 08-10 DECEMBER, 2011

spherical and cylindrical shell due to external loading in

Stress Analysis of Reactor Nozzle to Head Junction

A. Hardik B. Nayak and B. R. R. Trivedi A. Assistant Professor, Mechanical Engg. Department, Faculty of Engineering, Technology and Research, Bardoli B. Professor, Mechanical Engg. Department, Institute of Technology, Nirma University, Ahmedabad
Abstract Spherical heads are widely used in pressure vessels and piping systems of petrochemical and power plants. Under different loading conditions, the stress will occur at the nozzle to head or shell junction area. Due to discontinuity of the geometry, defect will occur and the junction region will become the weakest point which will be the failure source of the whole structure. Thus a reliable and accurate analysis method for head or shell to nozzle junction is necessary. In this paper, stress analysis is carried out for nozzle to head junction subjected to applied external load, internal pressure and moments. Stresses at reactor nozzle to head junction are obtained using Welding Research Council (WRC) 107 and PVCodeCalc software (2008) with and without stress indices. It is observed from the analysis that with the case of stress indices stress are very high in nature. So, an attempt is made to do the stress analysis of reactor nozzle to head junction using FEA software (ANSYS 12), as per ASME Section VIII Division 2.
Index termsStress analysis, Stress indices.

WRC. The methods published in WRC107 theoretical of Prof. Bijlaard, the formulations for calculation of the combined stress intensity. High stresses occurred at nozzle to head\shell junction which direct subjected to various forms of external loading on the nozzle. WRC 107 can find local stresses in spherical and cylindrical shells due to external loadings; it contains curves for hollow and solid circular junction. It determines local stresses at the eight points (Four upper and lower points) in the shell it shown in Figure 1.

I. INTRODUCTION ressure vessel is a closed container designed to hold gases or liquids at a pressure substantially different from the ambient pressure. Reactor is one type of pressure vessel. Pressure reactor is a device or process in which chemical reactions take place during a chemical conversion type of process. A reactor is a vessel designed for internal pressure or vacuum, has a heat source typically an external jacket, and is agitated for proper mixing. Martens and Massey [1] found stress at nozzle to shell junction using welding research council (WRC) 107[2] and finite element analysis. Moini and Mitchell [3] thick-walled pressure vessel with an attached nozzle under internal pressure is analyzed by using the finite element method. Raju P. P. [4] has presented a brief summary of the technical basis for the recommended

Fig.1 Local stresses in spherical shell

stress indices for 45 degree lateral connections under internal pressure and in-plane moment loadings. Welding Research Council Bulletin No 107 has been one of the most widely used Bulletins for finding local stresses in

As such the validity of Bijlaard's work is restricted to smaller diameter ratios (up to about d/D= 0.003). In WRC 107 the available graphs are based partially on the work of Bijlaard and partially on experimental data so that the ratio d/D could be extended to values of about 0.1. As per ASME section VIII division 2 part 5 ANNEX 5.D. [5] stress indices may be used to determine peak stresses around a nozzle opening. The term stresses index, is defined as the numerical ratio of the stress components t, n and r under consideration to the computed membrane hoop stress in the unreinforced vessel material; however, the material which increases the thickness of a vessel wall locally at the nozzle shall not be included in the calculation of the stress components. These stress directions are defined in Figure 2. Tables 5.D.5 in ASME give only the maximum stresses at certain general locations due to internal pressure. In the evaluation of stresses in or adjacent to vessel openings and

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connections, it is often necessary to consider the effect of stresses due to external loadings or thermal stresses.

Fig.3.Nozzle loads

The radial membrane and bending stress at eight points on nozzle to head junction are obtained using equation 1 to 6.
Fig.2 Direction of Stress Components

Radial membrane stress (P) Radial bending stress (P)

k n ( N x T / P )( P / T 2 ) ..(1)
..(2) ..(3) ..(4) ..(5) .(6)

In such cases, the combined stress at a given point may be determined by superposition. In the case of combined stresses due to internal pressure and nozzle loading, the maximum stresses for a given location should be considered as acting at the same point and added algebraically unless positive evidence is available to the contrary. II. MOTIVATION: Reactor has many discontinuous regions in their structures such as manhole connections, nozzles, supports, joints etc. They subjected to different types of loadings such as internal pressure, external pressure, thermal loads, lateral loads, etc. These discontinuous regions will become weakest points and more chance to failure of the whole structure. Thus a reliable and accurate analysis method for shell nozzle junction is necessary and there is scope for research stress analysis of reactor nozzle to head junction. . III. METHODOLOGY: Porter and Martens have presented methodology to calculate stresses and acceptance criteria for loads on nozzle to shell junctions on pressure vessels. First stage of present work finds stresses at nozzle to head junction by WRC 107 with and without stress indices. In the general case, all applied loads & moments must be resolved (at attachment shell interface) in the three principal direction; i.e. they must be resolved into components P, VL, VC, ML, MC and MT membrane, bending and shear stresses can be evaluated at eight distinct points in the shell at its juncture with the attachment. These eight points are shown in figure 1. All the nozzle loads and moments are considered to be acting at the same time, on conservative front. Nozzles external are shown in figure 3.

k b ( M x / P )(6 P / T 2 )

Radial membrane stress (Mc)

kn( N x T ( Rm T )1 / 2 / M 1 ) M 1 / T 2 ( RmT )1 / 2
Radial bending stress (Mc)

kb( M x ( Rm T )1 / 2 / M 1 )6 M 1 / T 2 ( Rm T )1 / 2
Radial membrane stress (ML)

k n ( N x ( R m T ) 1 / 2 / M 2 ) M 2 / T 2 ( R m T )1 / 2
Radial bending stress (ML)

k b ( M x ( R m T ) 1 / 2 / M 2 )6 M 2 / T 2 ( R m T ) 1 / 2

The tangential membrane and bending stress at eight points on nozzle to head junction are obtained using equation 7 to 12. Tangential membrane stress (P) k n ( N y T Tangential bending stress (P) Tangential membrane stress (Mc)

/ P)( P / T 2 ) .. (7)

k b ( M y / P )(6 P / T 2 ) ..(8)
..(9) ..(10) ..(11) ..(12)

kn( N y T ( RmT )1 / 2 / M 1 ) M 1 / T 2 ( RmT )1 / 2

Tangential bending stress (Mc)

kb( M y ( RmT )1 / 2 / M 1 )6M 1 / T 2 ( RmT )1 / 2

Tangential membrane stress (ML)

k n ( N y ( R m T ) 1 / 2 / M 2 ) M 2 / T 2 ( Rm T ) 1 / 2
Tangential bending stress (ML)

k b ( M y ( Rm T ) 1 / 2 / M 2 )6 M 2 / T 2 ( R m T ) 1 / 2

Local and general primary and secondary stresses at nozzle to head junction can be obtained with help of above equations results. After validated this WRC 107 stress results with PVCodeCalc 2008 software results with and without stress indices. With the case of considering stress indices the stresses at junction are very high in nature. So design is failed. Thus, stresses calculation at nozzle to head junction is carried out by finite element analysis using Ansys 12. Finite element model of nozzle on head is shown in figure 4.

INSTITUTE OF TECHNOLOGY, NIRMA UNIVERSITY, AHMEDABAD 382 481, 08-10 DECEMBER, 2011

3 72.1 mm 2187.0 mm 60 mm 131.5 mm 161.5 mm 323 mm 203 mm 4410 mm 4338 mm

Vessel thickness Vessel Mean Radius Nozzle thickness Nozzle Mean Radius Nozzle Outside Radius Nozzle OD Nozzle ID Vessel OD
Fig.4 Finite element model

Vessel ID

All the geometries are mapped meshed because the mapped mesh has very structured and ordered elements. The necessary partitions are made for accurate meshing which satisfies the quality check on the elements. Same mesh is used for static analysis. For evaluating the stresses due to structural loads, the top nodes of the vessel are fixed in axial and longitudinal directions. Stress classification line (SCL) is obtained by reducing two opposite sides of a Stress classification plane (SCP) to an infinitesimal length. SCL has been placed in the areas of the structure where the critical equivalent stress intensity is expected. Refer figure 5, for the location of SCL on the structure. Acceptance criteria acceptance criterion is taken as per ASME VIII, Division 2, Ed' 2007, ADD 2008. Part-5, paragraph 5.2.2.

Nozzle external loads applied at top of the nozzle neck. Nozzle loads are shown in Table I. Table I. Nozzle loads Nozzle Loads At Top Of the Nozzle Neck Fx, N 14398 Fy, N Fz, N Mx, N-mm My, N-mm Mz, N-mm 0 0 0 7490845 0

V. RESULT AND DISCUSSION: The following methodologies have been considered for nozzle to head junction under nozzle external loading, internal pressure and moments. 1. Stress analysis using WRC 107 with and without stress indices. 2. Stress analysis using PV-CodeCalc with and without stress analysis. PV-CodeCalc 2008 software (version of PV-Elite) is employed to calculate stresses of various components at attachment of reactor as per ASME. 3. Stress analysis using FE analysis in ANSYS 12. Table II. Results by WRC 107 and PV-CodeCalc software without stress indices.

Fig 5. Stress classification line.

IV. DESIGN DATA: Max. Allowable working pressure: 10 MPa Design Temperature: 426 C (699 K) Material of construction: Shell & Head: SA 387M GR.22 CL.2 [6] Nozzles: SA 336M GR.F22 CL. Geometry Inputs:

4 Type of Stress Int. Max. S.I WRC 107 (MPa) 153 176 241 Max. S.I PVCodeCalc (MPa) 152.79 176.03 242.24

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S.I. Allowable (MPa)

Result

Pm (SUS) Pm+Pl (SUS) Pm+Pl+Q (Total)

155.14 232.71 491.27

Passed Passed Passed

As already shown in Table II value of that maximum stress intensity obtained from WRC 107 and PV-CodeCalc software. WRC 107 results are validated with PV-CodeCalc results. Both results are meeting the requirements of Part 5 of ASME Section VIII, Div 2, Ed' 2007, ADD 2008.
Fig 6. Equivalent stress intensity plot for pressure plus nozzle loading.

Table III. Results by WRC 107 and PV-CodeCalc software with stress indices. Type Max. S.I Max. S.I S.I. Result of WRC107 PV Allowable Stress Int. (MPa) CodeCalc (MPa) (MPa) Pm (SUS) Pm+Pl (SUS) Pm+Pl+Q (Total) 331 342 389 336.13 347.11 395.02 155.14 232.71 491.27 Failed Failed Passed

Maximum & minimum stress intensity for internal pressure plus nozzle load is 329 MPa & 12.5 MPa respectively.

The stress evaluation is performed using WRC 107 & PVCodeCalc software with stress indices. WRC 107 results are validated with PV-CodeCalc results. General primary membrane equivalent stress (Pm) and General primary membrane equivalent stress plus local primary membrane equivalent stress (Pm+Pl) are not meeting the requirements of Part 5 of ASME Section VIII, Div 2, Ed' 2007, ADD 2008. As already shown in Table III value of that maximum stress intensity obtained from WRC 107 and PV-CodeCalc software does not fall under the allowable limits. In the case of considering stress indices, the design is failed. Nozzle to head junction analysis need to be done by finite element method. All the nozzle loads & moments are considered to be acting at the same time, on conservative front. Equivalent stress intensity plot for internal pressure plus nozzle load is shown figure 6.

Fig 7. Linearized stress intensity plot for pressure plus nozzle loading.

The accurate stress distance pattern for internal pressure plus nozzle load at the junction is shown figure 7. Here maximum membrane stress is 214.6 MPa, Maximum Membrane plus bending stress is 311.6 MPa at starting stress classification line (SCL) thickness & minimum is 135.1 MPa at 91 mm thickness. Maximum total stress is 323 MPa at starting SCL thickness and minimum is 160 MPa at 88 mm thickness. Linearization of stresses: The stress evaluation for each of the SCL and at the end nodal points of SCL is done as per Part 5.2.2.2 of code ASME Section VIII, Div 2, Ed' 2007, ADD 2008. The equivalent stress intensity at SCL and nodal end point of SCL is categorized as primary and primary plus secondary stresses as per code and the stress intensity are

INSTITUTE OF TECHNOLOGY, NIRMA UNIVERSITY, AHMEDABAD 382 481, 08-10 DECEMBER, 2011

checked with allowable limits. A computer program is made membrane and bending component is found along each defined path. The detail stress evaluation is as given below table IV. Table IV. Stress analysis Results by Ansys Type Of Stress Int. Pm+Pl Pm+Pl+Q Stress Int. Allow (MPa) 232.71 491.27 Max. S.I Ansys (MPa) 221.1 313.8 Result

because it considered the nozzle loads along with internal pressure. Its also gives the accurate stress distance pattern at the junction. VI. CONCLUSION The general solution obtained for nozzle to head junction have not given the results in allowable limits for WRC 107 & PV-CodeCalc software, because it does not take pressure into account while calculating the local and general primary membrane equivalent stress. It provides same nozzle load whether the nozzle is working under ambient pressure or working at high pressure. The stress evaluation of nozzle to head junction using FE analysis provides considerably more accurate stress data than closed form calculations such as WRC 107 as it gives results of stress profile around nozzle to head junction compared to results given at eight points by WRC107.

Passed Passed

The stress evaluation is performed and the stresses intensity are meeting the requirements of Part 5 of ASME Section VIII, Div 2, Ed' 2007, ADD 2008. It is also shown that the design of shell, head & nozzle are adequate as the stresses are within allowable limits. Table V. Stress analysis Results Type Of Stress Int. Stress Int. Allow (MPa) 232.71 491.27 Max.S.I PV-Code Calc (MPa) 347.11 395.02 Result Max. S.I Ansys MPa 221.1 313.8 Result

VII. REFERENCES [1] Martens D.H. and Massey S.R. "FEA analyses at nozzle/shell junctions subject to external load". International Journal of Pressure Vessels and Piping (Kansas), 1996. [2] Wichman K.R., Hooper A. G., and Mershon J.L. "local stresses in spherical and cylindrical shells due to external loadings." WRC bulletin no 107". Welding Research Councile bulletin 107, 1979. [3] Moini H and Mitchell P. T. "Stress analysis of a thick walled pressure vessel nozzle junction". International Journal of Pressure Vessels and Piping 46 (1991) 67-74 (California), pages 312-317, 1991. [4] Raju P. P. "development of stress indices for nonradial branch connections.". Nuclear Engineering and Design 98 (1987) 421-435, 198. [5] The America Society of Mechanical Engineers. "ASME boiler and pressure vessel code", section viii, division 2". The America Society of Mechanical Engineers, pages 674-728, 759-767, 2007.

Pm+Pl Pm+Pl+Q

Failed Passed

Passed Passed

As already shown in Table V value of that maximum stress intensity obtained from PV-CodeCalc and Ansys. General primary membrane equivalent stress plus local primary membrane equivalent stress (Pm+Pl) are not within allowable limits. Nozzle to head junction is failed because WRC 107 calculated stresses due to pressure thrust by the convectional formula of membrane theory and it is added to stress due to local load algebraically. General and Local primary membrane equivalent stresses are not allowable limit in WRC 107 and PV-CodeCalc at nozzle to head junction. General and Local primary stress depend on head thickness, internal pressure & head diameter of reactor. For obtaining stress analysis results within allowable limit, decreased head diameter with same thickness or increased thickness of head with same head diameter. In Finite elements analysis nozzle to head junction analysis General primary membrane equivalent stress plus local primary membrane equivalent stress (Pm+Pl) are meeting within allowable limits. Nozzle to head junction is passed

[6] The America Society of Mechanical Engineers. "ASME boiler and pressure vessel code", section ii, part d, division 2". The America Society of Mechanical Engineers, pages 440-449, 2007. [7] Moss. D. R. Pressure vessel design manual. Third Edition, pages 2-11,22-38, 2007. [8] I-deas NX-12 Modeling Software. [9] Ansys 12 Help. [10] Solid Edge ST2 Help. [11] PV-CodeCalc 2008 COADE Engineering Software.