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PVT 17 1193 AuthorProof
PVT 17 1193 AuthorProof
Bakry1
Faculty of Engineering,
Cairo University,
Shakedown Limits for Hillside
Orman, Giza 12613, Egypt
e-mail: ahmed.bakry@enppi.com Nozzles in Cylindrical Vessels
Chahinaz A. Saleh This research paper is concerned with the mechanical behavior of the cylindrical vessels
Associate Professor with hillside nozzles when subjected to both pressure and nozzle bending loads in cyclic
Solid Mechanics, forms. The influence of hillside angle on shakedown (SD) limits of the connection under
Faculty of Engineering, cyclic pressure and combined steady pressure with cyclic nozzle bending is investigated.
Cairo University, A shell finite element analysis model is built for the assembly using five different hillside
Orman, Giza 12613, Egypt angles ranging from 0 deg to 40 deg. Shakedown limits are determined by a direct tech-
e-mail: chahinaz@eng.cu.edu.eg nique known as the nonlinear superposition method (NSM). Bree diagrams for cyclic out
of plane opening (OPO)/in plane (IP) nozzle moments combined with steady internal
Mohammad M. Megahed pressure are determined. The results show an increase in both OPO and IP shakedown
Professor moments as the hillside angle is increased. In addition, the OPO shakedown limit
Solid Mechanics, moments for all hillside angles were found to be insensitive to the level of internal pres-
Faculty of Engineering, sure; this differs from the IP shakedown moment which starts to decrease with pressure
Cairo University, for the high pressures. [DOI: 10.1115/1.4039503]
Orman, Giza 12613, Egypt
e-mail: mmegahed@eng.cu.edu.eg
Introduction been investigated by Fang et al. [9]. The results indicated that the
maximum stresses are located at the acute corner in the transverse
Nozzles in cylindrical shells may be radial, oblique, or hillside
section of the intersection. The results also showed that the maxi-
depending on their function, accessibility, or routing of the con-
mum elastic stress and stress ratio decrease with the increase of
nected piping. A hillside nozzle in cylindrical shells is generally
hillside nozzle angle b.
used as an inlet connection aiming to achieve better fluid distribu-
Nozzle connections with pressure vessels are subjected to vari-
tion inside the vessel such as in distillation towers. A hillside noz-
ous combinations of steady and cyclic external nozzle piping
zle is also adopted when it is required to decrease inlet fluid
loads and internal fluid pressure. Such combinations can be exces-
velocity by defining a tangential circular path inside the vessel.
sive enough to cause fracture to the nozzle–cylinder connection if
Study of localized stresses induced at the vicinity of nozzle-
not properly designed. Under such circumstances, as mentioned
vessel intersections has long attracted the attention of both design-
above, the acting loads on the nozzle–cylinder junction may be of
ers and scholars. In this regard, WRC 107 [1] and WRC 297 [2]
cyclic nature. In such case, the pressure vessel engineer is
are two of the most cited bulletins of the Welding Research Coun-
required to ensure that modes of failure associated with cyclic
cil for evaluation of localized stresses at nozzle-vessel joints.
loading such as ratcheting or low cycle fatigue will not cause fail-
WRC 107 [1] is used for nozzles attached to both cylindrical and
ure of the nozzle–vessel intersection.
spherical vessels, while WRC 297 [2] is confined only to cylinder
Beyond elastic limit, a structure under cyclic loading may experi-
to cylinder intersections. In WRC 297, stresses in shell and nozzle
ence a state of “elastic shakedown” in which its steady-state behav-
are determined for wide range of diameters ratios.
ior is fully elastic after development of limited initial plastic strains
For intersections of hillside nozzles with cylindrical vessels, the
during the first few load cycles. Such a steady-state response is
ASME code [3] provided a formula for estimation of the ratio
desirable and ensures that no potential danger of failure exists.
between Sb (maximum stress in a hillside nozzle with angle b)
Determination of shakedown (SD) limits for structures involves
and S0 (maximum stress in a radial nozzle, b ¼ 0) due to internal
investigation of the cyclic inelastic response of the structure to
pressure as: Sb =S0 ¼ 1 þ 2ðsinbÞ2 which implies that the maxi-
cyclic loading. The first obvious approach to this end is to conduct
mum stress increases with the hillside angle b. On the basis of test
a full cyclic inelastic finite element (FE) analysis, which involves
results, Mershon [4] proposed that Sb =S0 ¼ ðcosbÞ0:5 , which
the application of load cycles in steps and monitoring the plastic
implies a slight reduction in the maximum stress as the hillside
strain. If the resulting plastic strain fields show that cyclic accumu-
angle b increases. Thus, the predictions of ASME approach are in
lation ceases after a few cycles and/or nonexistence of reversed
contradiction with experimental test results for maximum stress at
cyclic state of plastic strains, then it is concluded that elastic shake-
hillside nozzles.
down is achieved. However, such extensive computations may be
Wang et al. [5] presented experimental and numerical investi-
in many cases expensive and impractical for realistic structures.
gations of elastic stresses induced by internal pressure at the vicin-
For simple structures, it is possible to conduct such full cyclic
ity of hillside nozzle intersections with cylindrical shells. The
analysis analytically as illustrated by Bree [10] in his treatment of
results show that the stress concentration factor decreases with the
the behavior of a pressurized thin-walled tube under cyclic thermal
increase of hillside nozzle angle, thus confirming Mehrson conclu-
gradient across the wall. Bree results for the various modes of cyclic
sions. Further, Hazlett [6], Skopinsky [7], Rodabaugh [8] also
elastic plastic behavior (shakedown, ratcheting, and reversed plastic-
confirmed Mehrson result. This indicated that the ASME code [3]
ity (RP)) are illustrated in an interaction diagram known as the “Bree
is grossly over conservative.
diagram.” Megahed [11] conducted analytical investigations to illus-
Elastic stresses at hillside nozzle intersection with cylindrical
trate the effect of hardening rules on the modes of cyclic inelastic
vessels due to out-of-plane (OP) nozzle bending moment have
behavior of a two-bar structure under sustained mechanical load and
cyclic thermal gradient on a Bree like diagram.
1
Corresponding author. During the last two decades, a number of the so-called direct
Contributed by the Pressure Vessel and Piping Division of ASME for publication methods have been developed to determine shakedown loads
in the JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received September 25,
2017; final manuscript received February 25, 2018; published online April 10, 2018. without resort to conducting full cycle-by-cycle inelastic analysis.
Assoc. Editor: Steve J. Hensel. In addition to their simplicity, direct methods are less demanding
Table 1 Dimensions ( in mm) of the nozzle-vessel intersection dimensions of Abdalla’s model [25,26] are as following:
[28] D ¼ 508 mm, d ¼ 125 mm, T ¼ 8 mm, t ¼ 4 mm, i.e., d/D ¼ 0.25, t/
T ¼ 0.5, and D/T ¼ 63.5. The yield strength for both the nozzle and
Di L T do l t the cylinder materials was 302 MPa. For the current validation, FE
models similar to that illustrated in Fig. 3 above were constructed
400 800 5.4 133 300 4.3
by means of the parametric feature on ANSYS-WB to match the geo-
metries adopted in Abdalla’s work. The comparisons between Bree
diagrams generated here with Abdalla’s predictions for the valida-
vessel end boundary conditions would influence stresses or defor- tion cases are illustrated in Figs. 4 and 5 for IP and OP moment
mations at the junctions. Elastic stress analysis shows that discon- cases, respectively. In such diagrams, the abscissa represents a nor-
tinuity stresses arising at the nozzle junction decay after a malized measure of sustained load (P/PY), while the ordinate repre-
longitudinal distance of around 55 mm. Internal pressure was sents a normalized measure of cyclic load (M/MP), where
applied to all internal surfaces of both nozzle and vessel. The lon- PY ¼ 2Sy T=D is the internal pressure that is necessary to initiate
gitudinal effect of pressure was simulated by acting upon the cir- yielding in the cylindrical vessel and MP ¼ Sy d2 t is the fully plastic
cular end closures of nozzle and vessel by longitudinal stresses of moment of a straight pipe similar to the nozzle. Accordingly, the
magnitudes Pd/4t and PD/4T, respectively. Bending moments values of PY and MP for the nozzle–vessel intersections geometry
were applied to the nozzle end by means of a master node con- are: PY ¼ 9.5 MPa, MP ¼ 18.9 KN m.
nected to the nozzle circular closure. The FE model mesh adopted Figure 4 indicates that the current predictions for the case of IP
12 elements at the intersection fillet with element size around moment compare favorably with Ref. [25] with deviation of
4 mm. The maximum element size away from the intersection was around 3% in the low pressure range and a deviation of about 8%
about 35 mm. The FE model employed about 15,700 shell ele- for the high pressure range. The results presented in Fig. 5 for the
ments and 15,900 nodes. OP moment exhibit better correlation with Abdalla’s results [26]
with a deviation less than 2%. The correlation depicted in Figs. 4
and 5 indicates that the methodology and modeling adopted is
Validation of Finite Element Model. In order to validate the valid for use with nozzle intersections having hillside angle 0.
accuracy of the FE model and NSM procedure, the predictions pub-
lished by Abdalla [25,26] for shakedown behavior of radial nozzle Elastic Shakedown Results for Hillside
in cylindrical vessel under combined sustained pressure and cyclic Nozzle–Cylindrical Vessel Intersections
IP and OP moments are utilized. This special case of radial nozzle
was adopted for validation as no published literature could be The shakedown study for hillside nozzle in a cylindrical vessel
found for shakedown behavior of hillside nozzle with b 6¼ 0. In arrangement was performed for following load cases:
Abdalla’s work [25,26], the geometries and material properties Case 1: Cyclic pressure.
were similar to those of Wu et al. [29] and Sang et al. [30] for the Case 2: Steady pressure þ cyclic out-of-plane moment OPO.
cases of cyclic IP and OP nozzle moments, respectively. The Case 3: Steady pressure þ cyclic IP moment.
Fig. 2 Master model dimensions used in current research similar to Wang et al. [28]
Fig. 8 Comparison of elastic limit boundaries for different hill- Fig. 11 Location for SD critical element for b 5 10 deg model
side angle (d/D 5 0.32, t/T 5 0.8, and D/T 5 75.1) and cyclic moment
Fig. 9 Comparison of OPO shakedown load boundaries for dif- Fig. 12 Comparison of elastic limit boundaries for different
ferent hillside angle (b) (d/D 5 0.32, t/T 5 0.8, and D/T 5 75.1) hillside angle (b) for IP moment loading