INSTITUTE OF TECHNOLOGY, NIRMA UNIVERSITY, AHMEDABAD – 382 481, 08-10 DECEMBER, 2011 1

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
WRC. The methods published in WRC107 theoretical of
Abstract— Spherical heads are widely used in pressure Prof. Bijlaard, the formulations for calculation of the
vessels and piping systems of petrochemical and power combined stress intensity. High stresses occurred at nozzle to
plants. Under different loading conditions, the stress will head\shell junction which direct subjected to various forms of
occur at the nozzle to head or shell junction area. Due to external loading on the nozzle. WRC 107 can find local
discontinuity of the geometry, defect will occur and the stresses in spherical and cylindrical shells due to external
junction region will become the weakest point which will loadings; it contains curves for hollow and solid circular
be the failure source of the whole structure. Thus a junction. It determines local stresses at the eight points (Four
reliable and accurate analysis method for head or shell to upper and lower points) in the shell it shown in Figure 1.
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 PV-
CodeCalc 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 terms—Stress analysis, Stress indices.

I. INTRODUCTION

P 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.
Fig.1 Local stresses in spherical shell

As such the validity of Bijlaard's work is restricted to smaller

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
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
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 σt, σn and σr 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
2 INTERNATIONAL CONFERENCE ON CURRENT TRENDS IN TECHNOLOGY, ‘NUiCONE – 2011’

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) k n ( N x T / P )( P / T 2 ) ..(1)

In such cases, the combined stress at a given point may be

Radial bending stress (P) k b ( M x / P )(6 P / T 2 ) …..(2)
determined by superposition. In the case of combined stresses Radial membrane stress (Mc)
due to internal pressure and nozzle loading, the maximum kn( N x T ( Rm T )1 / 2 / M 1 ) M 1 / T 2 ( RmT )1 / 2 …..(3)
stresses for a given location should be considered as acting at Radial bending stress (Mc)
the same point and added algebraically unless positive
evidence is available to the contrary. kb( M x ( Rm T )1 / 2 / M 1 )6 M 1 / T 2 ( Rm T )1 / 2 …..(4)
Radial membrane stress (ML)
II. MOTIVATION: k n ( N x ( R m T ) 1 / 2 / M 2 ) M 2 / T 2 ( R m T )1 / 2 …..(5)
Radial bending stress (ML)
Reactor has many discontinuous regions in their structures
such as manhole connections, nozzles, supports, joints etc.
k b ( M x ( R m T ) 1 / 2 / M 2 )6 M 2 / T 2 ( R m T ) 1 / 2 ….(6)
The tangential membrane and bending stress at eight points
They subjected to different types of loadings such as internal
on nozzle to head junction are obtained using equation 7 to
pressure, external pressure, thermal loads, lateral loads, etc. 12.
These discontinuous regions will become weakest points and
more chance to failure of the whole structure. Thus a reliable
Tangential membrane stress (P) k n ( N y T / P)( P / T 2 ) .. (7)
and accurate analysis method for shell nozzle junction is Tangential bending stress (P) k b ( M y / P )(6 P / T 2 ) ..(8)
necessary and there is scope for research stress analysis of Tangential membrane stress (Mc)
reactor nozzle to head junction.
kn( N y T ( RmT )1 / 2 / M 1 ) M 1 / T 2 ( RmT )1 / 2 …..(9)
.
Tangential bending stress (Mc)
III. METHODOLOGY:
kb( M y ( RmT )1 / 2 / M 1 )6M 1 / T 2 ( RmT )1 / 2 …..(10)
Porter and Martens have presented methodology to calculate Tangential membrane stress (ML)
stresses and acceptance criteria for loads on nozzle to shell
junctions on pressure vessels. First stage of present work
k n ( N y ( R m T ) 1 / 2 / M 2 ) M 2 / T 2 ( Rm T ) 1 / 2 …..(11)
finds stresses at nozzle to head junction by WRC 107 with Tangential bending stress (ML)
and without stress indices. k b ( M y ( Rm T ) 1 / 2 / M 2 )6 M 2 / T 2 ( R m T ) 1 / 2 …..(12)
In the general case, all applied loads & moments must be
Local and general primary and secondary stresses at nozzle to
resolved (at attachment shell interface) in the three principal
head junction can be obtained with help of above equation’s
direction; i.e. they must be resolved into components P, VL,
results.
VC, ML, MC and MT membrane, bending and shear stresses
After validated this WRC 107 stress results with PV-
can be evaluated at eight distinct points in the shell at its
CodeCalc 2008 software results with and without stress
juncture with the attachment. These eight points are shown in
indices. With the case of considering stress indices the
figure 1. All the nozzle loads and moments are considered to
stresses at junction are very high in nature. So design is
be acting at the same time, on conservative front. Nozzles
failed. Thus, stresses calculation at nozzle to head junction is
external are shown in figure 3.
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

Vessel thickness 72.1 mm

Vessel Mean Radius 2187.0 mm

Nozzle thickness 60 mm

Nozzle Mean Radius 131.5 mm

Nozzle Outside Radius 161.5 mm

Nozzle OD 323 mm

Nozzle ID 203 mm

Vessel OD 4410 mm

Fig.4 Finite element model

Vessel ID 4338 mm

All the geometries are mapped meshed because the mapped

mesh has very structured and ordered elements. The necessary Nozzle external loads applied at top of the nozzle neck.
partitions are made for accurate meshing which satisfies the Nozzle loads are shown in Table I.
quality check on the elements. Same mesh is used for static
Table I. Nozzle loads
analysis. For evaluating the stresses due to structural loads,
the top nodes of the vessel are fixed in axial and longitudinal Nozzle Loads At Top Of the
directions. Nozzle Neck
Stress classification line (SCL) is obtained by reducing two Fx, N 14398
opposite sides of a Stress classification plane (SCP) to an
infinitesimal length. SCL has been placed in the areas of the Fy, N 0
structure where the critical equivalent stress intensity is
expected. Refer figure 5, for the location of SCL on the Fz, N 0
structure. Acceptance criteria acceptance criterion is taken as
per ASME VIII, Division 2, Ed' 2007, ADD 2008. Part-5,
paragraph 5.2.2. Mx, N-mm 0

My, N-mm 7490845

Mz, N-mm 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
Fig 5. Stress classification line.
stress indices.
IV. DESIGN DATA: 2. Stress analysis using PV-CodeCalc with and without
stress analysis. PV-CodeCalc 2008 software (version
Max. Allowable working pressure: 10 MPa of PV-Elite) is employed to calculate stresses of
Design Temperature: 426 °C (699 °K) various components at attachment of reactor as per
Material of construction: ASME.
Shell & Head: SA 387M GR.22 CL.2 [6] 3. Stress analysis using FE analysis in ANSYS 12.
Nozzles: SA 336M GR.F22 CL.
Geometry Inputs: Table II. Results by WRC 107 and PV-CodeCalc software
without stress indices.
4 INTERNATIONAL CONFERENCE ON CURRENT TRENDS IN TECHNOLOGY, ‘NUiCONE – 2011’

Type of Max. S.I Max. S.I S.I. Result

Stress Int. WRC PV- Allowable
107 CodeCalc (MPa)
(MPa) (MPa)

Pm 153 152.79 155.14 Passed

(SUS)
Pm+Pl 176 176.03 232.71 Passed
(SUS)
Pm+Pl+Q 241 242.24 491.27 Passed
(Total)

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. Maximum & minimum stress intensity for internal pressure
Type Max. S.I Max. S.I S.I. Result plus nozzle load is 329 MPa & 12.5 MPa respectively.
of WRC107 PV Allowable
Stress Int. (MPa) CodeCalc (MPa)
(MPa)

Pm 331 336.13 155.14 Failed

(SUS)
Pm+Pl 342 347.11 232.71 Failed
(SUS)
Pm+Pl+Q 389 395.02 491.27 Passed
(Total)

The stress evaluation is performed using WRC 107 & PV-

CodeCalc software with stress indices. WRC 107 results are
validated with PV-CodeCalc results. General primary
membrane equivalent stress (Pm) and General primary
Fig 7. Linearized stress intensity plot for pressure plus nozzle loading.
membrane equivalent stress plus local primary membrane
equivalent stress (Pm+Pl) are not meeting the requirements of
The accurate stress distance pattern for internal pressure plus
Part 5 of ASME Section VIII, Div 2, Ed' 2007, ADD 2008.
nozzle load at the junction is shown figure 7. Here maximum
As already shown in Table III value of that maximum stress
membrane stress is 214.6 MPa, Maximum Membrane plus
intensity obtained from WRC 107 and PV-CodeCalc software
bending stress is 311.6 MPa at starting stress classification
does not fall under the allowable limits.
line (SCL) thickness & minimum is 135.1 MPa at 91 mm
In the case of considering stress indices, the design is failed.
thickness. Maximum total stress is 323 MPa at starting SCL
Nozzle to head junction analysis need to be done by finite
thickness and minimum is 160 MPa at 88 mm thickness.
element method. All the nozzle loads & moments are
Linearization of stresses: The stress evaluation for each of the
considered to be acting at the same time, on conservative
SCL and at the end nodal points of SCL is done as per Part
front. Equivalent stress intensity plot for internal pressure
5.2.2.2 of code ASME Section VIII, Div 2, Ed' 2007, ADD
plus nozzle load is shown figure 6.
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 5

checked with allowable limits. A computer program is made because it considered the nozzle loads along with internal
membrane and bending component is found along each pressure. It’s also gives the accurate stress distance pattern at
defined path. The detail stress evaluation is as given below the junction.
table IV. VI. CONCLUSION

Table IV. Stress analysis Results by Ansys The general solution obtained for nozzle to head junction
have not given the results in allowable limits for WRC 107 &
Type Stress Int. Max. S.I Result PV-CodeCalc software, because it does not take pressure into
Of Allow Ansys account while calculating the local and general primary
Stress Int. (MPa) (MPa) membrane equivalent stress. It provides same nozzle load
whether the nozzle is working under ambient pressure or
Pm+Pl 232.71 221.1 Passed working at high pressure.
The stress evaluation of nozzle to head junction using FE
Pm+Pl+Q 491.27 313.8 Passed
analysis provides considerably more accurate stress data than
closed form calculations such as WRC 107 as it gives results
The stress evaluation is performed and the stresses intensity of stress profile around nozzle to head junction compared to
are meeting the requirements of Part 5 of ASME Section VIII, results given at eight points by WRC107.
Div 2, Ed' 2007, ADD 2008. It is also shown that the design
of shell, head & nozzle are adequate as the stresses are within VII. REFERENCES
allowable limits.
[1] Martens D.H. and Massey S.R. "FEA analyses at
Table V. Stress analysis Results
nozzle/shell junctions subject to external load".
Type Stress Max.S.I Result Max. Result International Journal of Pressure Vessels and Piping
(Kansas), 1996.
Of Int. PV-Code S.I
[2] Wichman K.R., Hooper A. G., and Mershon J.L. "local
Stress Int. Allow Calc Ansys stresses in spherical and cylindrical shells due to external
(MPa) (MPa) MPa loadings." WRC bulletin no 107". Welding Research
Councile bulletin 107, 1979.
Pm+Pl 232.71 347.11 Failed 221.1 Passed [3] Moini H and Mitchell P. T. "Stress analysis of a thick
walled pressure vessel nozzle junction". International
Pm+Pl+Q 491.27 395.02 Passed 313.8 Passed 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
As already shown in Table V value of that maximum stress branch connections.". Nuclear Engineering and Design
intensity obtained from PV-CodeCalc and Ansys. General 98 (1987) 421-435, 198.
primary membrane equivalent stress plus local primary [5] The America Society of Mechanical Engineers. "ASME
boiler and pressure vessel code", section viii, division 2".
membrane equivalent stress (Pm+Pl) are not within allowable
The America Society of Mechanical Engineers, pages
limits. Nozzle to head junction is failed because WRC 107 674-728, 759-767, 2007.
calculated stresses due to pressure thrust by the convectional
formula of membrane theory and it is added to stress due to
local load algebraically. [6] The America Society of Mechanical Engineers. "ASME
General and Local primary membrane equivalent stresses are boiler and pressure vessel code", section ii, part d,
division 2". The America Society of Mechanical
not allowable limit in WRC 107 and PV-CodeCalc at nozzle
Engineers, pages 440-449, 2007.
to head junction. General and Local primary stress depend on [7] Moss. D. R. Pressure vessel design manual. Third Edition,
head thickness, internal pressure & head diameter of reactor. pages 2-11,22-38, 2007.
For obtaining stress analysis results within allowable limit, [8] I-deas NX-12 Modeling Software.
decreased head diameter with same thickness or increased [9] Ansys 12 Help.
thickness of head with same head diameter. [10] Solid Edge ST2 Help.
In Finite elements analysis nozzle to head junction analysis [11] PV-CodeCalc 2008 COADE Engineering Software.
General primary membrane equivalent stress plus local
primary membrane equivalent stress (Pm+Pl) are meeting
within allowable limits. Nozzle to head junction is passed