PD Cen TR 13445-101-2015

PD CEN/TR 13445-101:2015
BSI Standards Publication
Unfired pressure vessels

Part 101: Example of application
PD CEN/TR 13445-101:2015 PUBLISHED DOCUMENT
National foreword
This Published Document is the UK implementation of CEN/TR
13445-101:2015.
The UK participation in its preparation was entrusted to Technical
Committee PVE/1, Pressure Vessels.
A list of organizations represented on this committee can be
obtained on request to its secretary.
This publication does not purport to include all the necessary
provisions of a contract. Users are responsible for its correct
application.
© The British Standards Institution 2015. Published by BSI Standards
Limited 2015
ISBN 978 0 580 87642 4
ICS 23.020.30
Compliance with a British Standard cannot confer immunity from
legal obligations.
This Published Document was published under the authority of the
Standards Policy and Strategy Committee on 30 September 2015.
Amendments issued since publication
Date Text affected
PD CEN/TR 13445-101:2015
TECHNICAL REPORT CEN/TR 13445-101

RAPPORT TECHNIQUE
TECHNISCHER BERICHT April 2015
ICS 23.020.30
English Version
Unfired pressure vessels - Example of application
Récipients sous pression non soumis à la flamme - Partie Unbefeuerte Druckbehälter - Teil 101: Anwendungsbeispiel
101 : Exemple d'application
This Technical Report was approved by CEN on 10 February 2015. It has been drawn up by the Technical Committee CEN/TC 54.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United
Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2015 CEN All rights of exploitation in any form and by any means reserved Ref. No. CEN/TR 13445-101:2015 E
worldwide for CEN national Members.
PD CEN/TR 13445-101:2015
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Contents Page
Foreword ...................................................................................................................................................................... 3
1 Scope .............................................................................................................................................................. 4
2 Normative references .................................................................................................................................... 4
3 Presentation of example ............................................................................................................................... 5
3.1 General ............................................................................................................................................................ 5
3.2 Pressure vessel data ..................................................................................................................................... 5
3.3 PED 97/23/CE Category ................................................................................................................................. 7
3.4 Extracts from EN 13445-1 to EN 13445-5:2009 and from others standards ............................................ 7
4 Materials ......................................................................................................................................................... 7
4.1 General ............................................................................................................................................................ 7
4.2 Minimum requirements for materials .......................................................................................................... 7
4.3 Mechanical properties of the chosen materials ......................................................................................... 9
4.4 Type of material certificate ......................................................................................................................... 12
4.5 Prevention of brittle fracture ...................................................................................................................... 13
4.6 Particular Material Appraisal (PMA) ........................................................................................................... 25
5 Calculations and design ............................................................................................................................. 26
5.1 General .......................................................................................................................................................... 26
5.2 Definitions related to pressure ................................................................................................................... 26
5.3 Thickness definitions and joint coefficient ............................................................................................... 27
5.4 Prevention of brittle fracture ...................................................................................................................... 28
5.5 Maximum allowed values of the nominal design stress .......................................................................... 28
5.6 Calculations and design ............................................................................................................................. 30
6 Fabrication .................................................................................................................................................... 68
6.1 General .......................................................................................................................................................... 68
6.2 Minimum requirements for fabrication ...................................................................................................... 69
6.3 Production tests........................................................................................................................................... 72
6.4 Forming of shell ........................................................................................................................................... 76
6.5 Post weld heat-treatment (PWHT) .............................................................................................................. 82
6.6 Others requirements ................................................................................................................................... 84
7 Inspection and testing ................................................................................................................................. 84
7.1 General .......................................................................................................................................................... 84
7.2 Performance of inspection and testing ..................................................................................................... 85
7.3 Technical documentation ........................................................................................................................... 85
7.4 Inspection and testing during fabrication ................................................................................................. 85
7.5 Others requirements ................................................................................................................................... 91
7.6 Final assessment ......................................................................................................................................... 91
7.7 Marking and declaration of compliance with the standard ..................................................................... 94
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Foreword
This document (CEN/TR 13445-101:2015) has been prepared by Technical Committee CEN/TC 54 “Unfired
pressure vessels”, the secretariat of which is held by BSI.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights.
CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
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1 Scope
This Technical Report presents an application of EN 13445 through an example of design and fabrication of an
unfired pressure vessel. Every step is described as far as possible:
— Material choice;
— Design and calculation;
— Fabrication;
— Inspection and testing;
using the following part of EN 13445:
— EN 13445-1:2009;
— EN 13445-2:2009;
— EN 13445-3:2009;
— EN 13445-4:2009;
— EN 13445-5:2009 .
As applicable, some choices for design or fabrication are made according to “the state of art” practice.
Some parts of EN 13445 are reproduced in order to show which requirements are relevant to the design and
fabrication of the target vessel.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are indispensable
for its application. For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments) applies.
EN 287-1:2004+A2:2006, Approval testing of welders — Fusion welding — Part 1: Steels
EN 473:2008, Non-destructive testing — Qualification and certification of NDT personnel — General principles
EN 764-5:2002, Pressure Equipment — Part 5: Compliance and Inspection Documentation of Materials
EN 1092-1:2007, Flanges and their joints — Circular flanges for pipes, valves, fittings and accessories, PN
designated
EN 1418:1997, Welding personnel — Approval testing of welding operators for fusion welding and resistance weld
setters for fully mechanized and automatic welding of metallic materials
EN 1515-3:2005, Flanges and their joints — Bolting — Part 3: Classification of bolt materials for steel flanges, class
designated
EN 1515-4:2009, Flanges and their joints — Bolting — Part 4: Selection of bolting for equipment subject to the
Pressure Equipment Directive 97/23/EC
EN 1759-1:2004, Flanges and their joint — Circular flanges for pipes, valves, fittings and accessories, Class
designated — Part 1: Steel flanges, NPS 1/2 to 24
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EN 10025-2:2004, Hot rolled products of structural steels — Part 2: Technical delivery conditions for non-alloy
structural steels
EN 10028-1:2007, Flat products made of steels for pressure purposes — Part 1: General requirements
EN 10028-2:2003, Flat products made of steels for pressure purposes — Part 2: Non-alloy and alloy steels with
specified elevated temperature properties.
EN 10029:2010, Hot-rolled steel plates 3 mm thick or above —Tolerances on dimensions and shape
EN 10204:2004, Metallic products — Types of inspection documents.
EN 10216-3:2002, Seamless steel tubes for pressure purposes — Technical delivery conditions — Part 3: Alloy
fine grain steel tubes
EN 10222-4:1998, Steel forgings for pressure purposes — Part 4: Weldable fine grain steels with high proof
strength.
EN 10269:1999+A1:2006, Steels and nickel alloys for fasteners with specified elevated and/or low temperature
properties
EN 12560-4:2001, Flanges and their joints — Gaskets for Class-designated flantes — Part 4: Corrugated, flat or
grooved metallic and filled metallic gaskets for use with steel flanges
CR ISO 15608:2000, Welding — Guidelines for a metallic material grouping system (ISO/TR 15608:2000)
EN ISO 15614-1:2004, Specification and qualification of welding procedures for metallic materials — Welding
procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys (ISO 15614-
1:2004)
3 Presentation of example
3.1 General
The target vessel consists of several components:
— a cylindrical shell,
— two elliptical ends,
— a welding neck flange,
— a nozzle,
— two saddle supports arranged symmetrically
3.2 Pressure vessel data
The data specified for the present example are the following:
— Vessel data:
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Key
Di = 3 468 mm
L = 20 000 mm (cylindrical shell length)
Figure 1 — Pressure vessel data
Material: steel
— Service data:
Normal service conditions:
— Internal pressure: 44 bar
— Maximum temperature: 50 °C
— Minimum metal temperature: -20 °C
— Liquid group 1, density: 0,54
— Pressure loading predominantly of non-cyclic nature
There are not exceptional service conditions.
PED 97/23/CE regulation applies.
The calculation of all components is performed by formulas (DBF: Design By Formula). According to the specified
operating conditions, the pressure vessel is neither subjected to fatigue nor to creep.
It is supposed that there is only a risk of atmospheric corrosion during operation of the vessel. Thus, a corrosion
allowance of 3 mm is added.
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3.3 PED 97/23/CE Category
The maximum allowable pressure PS used as a first approach is 44 bar and the fluid is a liquid of group 1.
The category which applied for the target vessel is category II as defined in Clause 3 paragraph 1.1(b) of the PED
which indicates the use of Table 3 of Annex II of PED to set the category.
3.4 Extracts from EN 13445-1 to EN 13445-5:2009 and from others standards
The extracts from the EN 13445 Standard clauses which are the most relevant at each step of the example are
reproduced in black frames. When necessary, the adequate requirements in these extracts are framed in red.
Other extracts of standards referenced in EN 13445 are reproduced, also in black frames, and the standard from
which they are extracted is mentioned. When necessary, the adequate requirements in these extracts are framed
in red.
4 Materials
4.1 General
EN 13445-2:2009 gives the minimum requirements to be fulfilled for steel entering the manufacturing of pressure
vessel. The informative Annex E of this standard references European materials usable for pressure vessel
manufacturing. The corresponding steel grades come from harmonized European standards. The Grouping
according to CEN ISO/TR 15608:2000 is also given for each grade.
The minimum requirements concern elongation, impact test and chemical composition. These requirements for
steel should ensure toughness and good behaviour of materials during manufacturing (weldability and forming).
Table 4.1-1 of this report summarizes some properties of the materials which have been chosen for fabrication of
the target vessel. This table shows how the requirements of EN 13445-2:2009 are fulfilled.
4.2 Minimum requirements for materials
4.2.1 General
The following clauses of EN 13445-2:2009 shall be fulfilled:
4.2.2 Minimum elongation
The requirements for minimum elongation are fulfilled by the chosen materials, see Table 4.1-1.
Figure 2 — Abstract from EN 13445-2:2009
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4.2.3 Impact test for ferritic steel
The requirements for impact test are fulfilled by the chosen materials, see Table 4.1-1. Requirements of Annex B of
EN 13445-2:2009 shall also apply; see 4.5 of this report.
4.2.4 Chemical composition of selected grade
The requirements for chemical composition are fulfilled by the chosen materials, see Table 4.1-1, except for the
bolting grade 42CrMo4 (1.7225), but this product is not intended for welding or forming as stated in 4.1.7 of
EN 13445-2:2009. Indeed, following EN 10269:1999, EN 10269:1999+A1:2006, the specified chemical composition
for this grade of bolting is:
— %C: 0,38 to 0,45;
— % P: 0,035 max;
— % S: 0,035 max.
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4.3 Mechanical properties of the chosen materials
The selected grades and their appropriate properties are summarized in Table 4.1-1.
All the mechanical properties presented in this table are minimum values from transversal specimen and are
specified in the relevant technical specification. Transversal specimens are defined as specimen taken in a
direction perpendicular to the direction of principal deformation of the product (e.g. for flat products the transversal
direction is perpendicular to the rolling direction).
Since the minimum yield strength and tensile strength values are specified in the material technical specification as
a function of the product thickness the values to be used for the design of each specific component are not known
at first. They can be set only once the design calculations performed according to the relevant EN 13445-3:2009
rules have shown that the thickness assumed for calculation is acceptable. In some cases an iteration on the
thickness and the corresponding mechanical properties is necessary to get the correct values (see Clause 5 of this
report).
For determination of the material characteristics above 20 °C, the interpolation rules which apply are those defined
in 4.2.2 of EN 13445-2:2009:
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Table 4.1-1
Specified
Specified Specified
minimum Impact
minimum Specified minimum minimum
yield energy Classification
Grades yield strength tensile strength elongation Heat
strength KCV according to
Component Standard(s) (Steel at room at room temperature after fracture treatment
at 50 °C (EN 13445- CR
Number) temperature Rm A% condition
2:2009, ISO 15608:2000
Rp0,2 (MPa) (EN 13445-
Rp0,2/t 4.1.6)
(MPa) 2:2009, 4.1.4)
(MPa)
Cylindrical EN 10028- P295GH 27 J @

285 276 460 21 +N 1.2
shell 2:2003 (1.0481) -20 °C
EN 10028- P295GH 27 J @
Elliptical end 285 276 460 21 +N 1.2
2:2003 (1.0481) -20 °C
EN 10216- P275NL2 EN 13445- 47 J @

Nozzle 275 390 22 +N 1.1
3:2002 (1.1104) 2:2009, 4.2.2 -20 °C
EN 1759-
1:2004 P285QH EN 13445- 27 J @
Flange 255 390 23 +QT 1.2
EN 10222- (1.0478) 2:2009, 4.2.2 -20 °C
4:1998
EN 10269:199 42CrMo4 40 J @
Bolting 730 720 860 14 +QT 3.2
9 (1.7225) -40 °C
Reinforcing EN 10028- P295GH 27 J @

285 276 460 21 +N 1.2
plate 2:2003 (1.0481) -20 °C
EN 10025-2: S275J2 27 J @
Saddle support 275 No value 430 21 +N 1.1
2004 (1.0145) -20 °C
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4.4 Type of material certificate
4.4.1 PED requirements
Annex I paragraph 4.3 of the PED states that for the Category II main pressure-bearing parts of pressure
equipment, the material certificate shall be a certificate of specific control. In accordance with EN 10204:2004, this
certificate shall be, as a minimum, of type 3.1.
4.4.2 Type of certificate for pressure vessel components
Material certificate may be selected in accordance with EN 764-5:2002 which specifies the type of material
certificate to obtain from the material producer following the considered part (main pressure-bearing parts, pressure
parts other than main pressure-bearing parts or non pressure-bearing parts).
Figure 1 of EN 764-5:2002 below is useful to determine the type of certificate:
NOTE Edition of EN 10204:1991 is used for application of EN 764-5:2002 and edition of EN 10204:2004 is
used for application of EN 13445-2:2009. Type 3.1B of EN 10204:1991 is replaced by 3.1 of EN 10204:2004.
Types 3.1A and 3.1C is replaced by 3.2 of EN 10204:2004.
Table 4.4.2-1 below summarizes the type of material certificate according to EN 764-5:2002:
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Table 4.4.2-1
Minimum type of certificate according
Components Type of components
to EN 10204:2004
Cylindrical shell Main pressure-bearing parts 3.1 (3.1B as defined in EN 10204:1991)
Elliptical end Main pressure-bearing parts 3.1 (3.1B as defined in EN 10204:1991)
Pressure part other than main pressure-
Nozzle 2.2
bearing parts
Flange 2.2
bearing parts
Bolting 2.2
bearing parts
Reinforcing plate (for
Non-pressure-bearing parts 2.2
saddle support)
Saddle support Non-pressure-bearing parts 2.2
NOTE The type of certificate for the saddle support reinforcing plate could be of type 3.1 because the
material grade is chosen for being the same as for the cylindrical shell. To manufacture the reinforcing plate, the
vessel manufacturer could use a plate from the lot used to manufacture the cylindrical shell.
4.5 Prevention of brittle fracture
4.5.1 General
Annex B of EN 13445-2:2009 proposes three methods to prevent the risk of brittle fracture. The two first methods
are applied to the target vessel. The last one, Method 3, is not used because it would need to perform a complete
fracture mechanics analysis.
4.5.2 Method 1 (B.2.2 of EN 13445-2:2009)
4.5.2.1 General
As stated in B.2.2.1 of EN 13445-2:2009, Method 1 permits to select steels taken from harmonized European
standards. The assumptions are that TR = T27J = TKV and the required toughness values shall be obtained after
manufacturing.
4.5.2.2 Determination of test temperature TKV
The Tables in B.2.2 give reference temperature TR as a function of grade, reference thickness (depending on
whether PWHT is performed or not). Corresponding table for each product shall apply for each type of products.
Results corresponding to PWHT shall be taken into account (see 6.5.2 of this report):
— Plates and strip
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— Tubes

— Forgings
— Nuts and bolts
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4.5.3 Method 2 (Clause B.2.3 of EN 13445-2:2009)
4.5.3.1 General
Method 2 may be used to derive a reference temperature TR that is lower than the one derived from Method 1.
4.5.3.2 Definitions
The following definitions are given by EN 13445-2:2009 and apply:
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4.5.3.3 Impact energy requirements
Table B.2-13 gives also the required impact energy KV on a 10 mm x 10 mm test piece, KV = 27 J. The parent
material, heat affected zone and welds shall meet this impact energy at the impact test temperature TKV derived
from Method 2.
4.5.3.4 Determination of the test temperature TKV
4.5.3.4.1 Components and welded joints
A PWHT is applied for some welded joints as described in 6.5.2.1 of this report.
The reference temperature is defined as being TR = TM = -20 °C.
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Diagrams permit the determination of the impact test temperature TKV. The relevant ones shall be selected from
Table B.2-13 of EN 13445-2: 2009 here-above.
The reference thickness eB is determined from Table B.4-1 of EN 13445-2:2009. The way to obtain TKV from the
values of TR and eB in the relevant diagram is illustrated for each construction detail of the target vessel in
Table 4.5.3.4.1-1 to Table 4.5.3.4.1-4 of this report.
There is no construction detail applying to longitudinal seam welds and to circumferential seam welds in the
cylindrical shell. In other words, the construction detail No.1 does not apply because it makes reference to butt
welded components of unequal thickness.
Therefore, for these welded joints, the reference thickness eB is equal to the nominal thickness of the component,
i.e. 45 mm.
Then, Figure B.2-3 of EN 13445-2:2009 applies to derive TKV (see Table 4.5.3.4.1-1 below).
Table 4.5.3.4.1-1 — Longitudinal and circumferential seam welds in cylindrical shell
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Table 4.5.3.4.1-2 — Base material of cylindrical shell and elliptical end –

Circumferential joint between cylindrical shell and elliptical end
The reference thickness eB is determined as follows:
— For the cylindrical shell, eB is defined by Part A and is referenced as e1 (TKV is equal to 0 °C, see
Table 4.5.3.4.1-1 of this report).
— For the elliptical end, eB is defined by Part B and is referenced as e3. The diagram used is the one of Figure
B.2-3 (TKV is equal to -6 °C, see Table 4.5.3.4.1-2 above).
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— For the weld, eB is referenced as e2 and is taken as equal to 50 mm to be conservative. The diagram used is
the one of Figure B.2-3 (see Table 4.5.3.4.1-2 above).
Table 4.5.3.4.1-3 — Construction detail for the branch
— For the cylindrical shell, eB is defined by Part A and is referenced as e2; the diagram used to determine the
impact test temperature TKV for the cylindrical is that of Figure B.2-3 of EN 13445-2:2009 (Re ≤ 355 MPa, see
Table 4.5.3.4.1-1 of this report).
— For the nozzle, eB is defined by Part B and is referenced as e1, Figure B.2-1 (see Table 4.5.3.4.1-3 of this
report) of EN 13445-2:2009 shall be used.
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— For the weld, eB is referenced as e2 or e3 (the thickness of the cylindrical shell and of the reinforcing plate is
the same) and the diagram used to determine the impact test temperature TKV for the weld is that of Figure
B.2-3 of EN 13445-2:2009 (Re ≤ 355 MPa, see Table 4.5.3.4.1-1 of this report).
For the nozzle (Part B), eB is less than 20 mm, B.2.3.2 of EN 13445-2:2009 shall apply:
It is not possible to determine TKV from TR because the intersection point with the curve for 20 mm falls outside the
diagram.
If one assumes an impact test temperature TKV = 20 °C, the permitted TR is -53,1 °C which is below the reference
temperature of the target vessel (-20 °C). Thus, the considered TKV value is confirmed and is equal to 20 °C.
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Table 4.5.3.4.1-4 — Construction detail for the welding neck flange and the nozzle
— For the flange, eB is defined by Part A and shall be the one determined from the requirement given by the Note
a of the Table B.4-1 of EN 13445-2:2009:
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Therefore, e2 (12,5 mm) is applied to Figure B.2-2 for as-welded condition and ef/4 (63,5 / 4 = 15,875 mm) is
applied to Figure B.2-1 for non-welded condition (see Table 4.5.3.4.1-4 above).
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Table 4.5.3.4.1-4 — Construction detail for the welding neck flange and the nozzle (continued)
— For the nozzle (Part B) eB is referenced as e1, the diagram used to determine the impact test temperature TKV
for the nozzle is the one of Figure B.2-1 (Re ≤ 275 MPa, see Table 4.5.3.4.1-3 of this report).
— For the weld, eB is referenced as e2, the diagram used to determine the impact test temperature TKV is the one
of Figure B.2-2 (Re ≤ 265 MPa, see Table 4.5.3.4.1-4 of this report).
In that case, all the reference thicknesses eB are less than 20 mm, and B.2.3.2 of EN 13445-2:2009 shall apply:
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It is not possible to determine TKV from TR because the intersection with the curve for 20 mm falls outside the
diagrams.
If one assumes an impact test temperature TKV = 20 °C, the permitted TR for each part is the following:
— For the flange (Part A), two verifications shall be performed:
— the one by using Figure B.2-2: TR = -25 °C,
— the other by using Figure B.2-1: TR = -53,1 °C
— For the nozzle (Part B), by using Figure B.2-1: TR = -53,1 °C
— For the weld, by using Figure B.2-2: TR = -25 °C
Therefore, the reference temperature to retain is the greatest: TR = -25 °C. This temperature is lower than the
reference temperature of the target vessel (-20 °C). Thus, the considered TKV value is confirmed and is equal to
20 °C.
4.5.3.4.2 Summary of TKV applying to components and welded joints
The resulting TKV for each component (base material) is summarized in Table 4.5.3.4.2-1 below:
Table 4.5.3.4.2-1 — TKV for base material

Construction details from
Components Table B.4-1 of EN 13345- eB (mm) TKV (°C)
2:2009
Cylindrical shell 1 e1 = 45 0
Elliptical end 1 e3 = 50 -6
Nozzle 3 or 10 e1 = 12,5 20
e2 = 12,5
(as-welded condition,
Flange 10 Note a of Table B.4-1 of 20
EN 13445-2:2009 shall
apply)
The resulting TKV for each welded joint is summarized in Table 4.5.3.4.2-2 below:
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Table 4.5.3.4.2-2 — TKV for welded joints

Construction details from
Components Table B.4-1 of EN 13345- eB (mm) TKV (°C)
2:2009
Cylindrical shell to
1 e2 = 50 -6
elliptical end
Branch and Nozzle 3 e2 = 45 0
Flange to nozzle 10 e2 = 12,5 20
Longitudinal seam welds
N/A e2 = 45 0
in cylindrical shell
Circumferential seam
N/A e2 = 45 0
welds in cylindrical shell
N/A: Non Applicable
For the material supplying, impact test temperature should be modified from the one given by the specification for
material supplying. The base material TKV values determined from the rules of Annex B of EN 13445-2:2009 should
be specified.
For welded joints, see 6.2.3 of this report.
4.6 Particular Material Appraisal (PMA)
The pressure vessel manufacturer may use a material which is not issued from a European harmonized standard
for main pressure bearing-parts as cylindrical shell and elliptical ends. For instance, manufacturer may use an
ASME specification, e.g. SA 516 (2013 edition), which is the “Specification for pressure vessel plates, carbon steel,
for moderate and lower temperature service”. The selected grade is the grade 70 which is non-alloyed steel. This
specification should be used together with ASME SA-20 (2013 edition) which is the “Specification for general
requirements for steel plates for pressure vessels”.
As a minimum, the following ordering information should be specified for mechanical test:
— Tension test following ASME SA 370 (2013 edition):
— Minimum yield strength: 260 MPa,
— Elongation:
— in 8”: 17% minimum
— in 2”: 21% minimum
— Impact test following ASME SA 370 (striker radius of 8 mm):
— 20 J (minimum average for three specimens) at -40 °C (for thicknesses over 25 mm to 50 mm includes)
following ASME SA-20 (2013 edition)
Since ASME specification is not European harmonized standard and since there is not a European Approval of
Materials (EAM) available, a Particular Material Appraisal (PMA) shall be provided by the manufacturer and
requirements of Annex I paragraph 7.5 of PED 97/23/CE shall be fulfilled. In this case, mechanical test shall be the
following:
— Tension test following EN ISO 6892-1:2009:
— Minimum yield strength: 260 MPa,
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— Elongation with a length gauge of 5,65 S0 (So is the initial section of specimen):
— 14 % minimum
— Impact test following EN ISO 148-1:2010: (striker radius of 2 mm, an impact energy called KV2 shall be
specified):
— 27 J (minimum average for three specimens) at TKV = 0 °C for the cylindrical shell and TKV = -6 °C for
the elliptical end as determined in 4.5.3.4 of this report
Moreover, a limitation of carbon content of 0,25 % can be applied, ASME SA 516 (2013 edition) specifying 0,28 %
as a maximum for grade 70.
5 Calculations and design
5.1 General
In this Clause 5 of this report, design by formulas proposed by EN 13445-3:2009 will be used to determine the
required thicknesses and therefore the nominal thicknesses of pressure vessel’s components.
Verification of opening and of the resistance of the shell on two symmetrically saddle supports is also performed.
Normal operating load case and test load case are taken into account.
The reference number connected to each formula is the one used in EN 13445-3:2009. Therefore, it has no
correspondence with Paragraph number of this report.
5.2 Definitions related to pressure
EN 13445-3:2009 gives definition about the pressures which are to be considered in calculation:
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For the target vessel, it is assumed that the design pressure Pd is equal to the calculation pressure P. Therefore
P = Pd = 44 bar.
5.3 Thickness definitions and joint coefficient
5.3.1 Thicknesses
The definitions of the thicknesses are given in Clause 3 and also in 5.2.3 of EN 13445-3:2009 with Figure 5-1
which is reproduced below:
5.3.2 Joint coefficient
The value of the joint coefficient to be used for calculation of the required thickness of shells shall follow the
requirement of 5.6 of EN 13445-3:2009.
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Then, the joint coefficient applies only to normal operating cases and, for the target vessel, only for longitudinal
welds in cylindrical shell.
One assumes a fabrication with testing according to testing group 1. Accordingly, z = 1, (see 7.4.2 of this report).
5.4 Prevention of brittle fracture
Brittle fracture is prevented through the respect of the requirements of 5.4.8 of EN 13445-3:2009.
5.5 Maximum allowed values of the nominal design stress
The formulas for determination of the nominal design stresses are given in Table 6-1 of EN 13445-3:2009.
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For bolting, in the case of a flange assembly, the nominal design stresses are defined in Clause 11.4.3.1 of
EN 13445-3:2009:
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Table 5.5-1
Testing and exceptional
Components Material Normal operating load cases
load cases
 
276 460  285
Cylindrical shell fd = MIN  ; = 184 MPa ftest = = 271,43 MPa
 1,5 2,4  1,05
 
 
276 460  285
Elliptical end fd = MIN  ; = 184 MPa ftest = = 271,43 MPa
Steels other than  1,5 2,4  1,05
austenitic  
 
275 390  275
Nozzle
A < 30 % fd = MIN  ; = 162,5 MPa ftest = = 261,90 MPa
 1,5 2,4  1,05
 
 
255 390  255
Flange fd = MIN  ; = 162,5 MPa ftest = = 242,86 MPa
 1,5 2,4  1,05
 
 730 860  ftest = 1,5fd = 322,5 MPa

Carbon and non-
Bolting fd = MIN  ;  = 215 MPa
austenitic steels  3 4 
 
NOTE The materials for reinforcing plates and saddle supports are not mentioned in this table because the present
example covers only the calculation of the vessel, not that of its supports.
5.6 Calculations and design
5.6.1 Normal operating load case
5.6.1.1 General
5.3.2.1 of EN 13445-3:2009 defines load cases for normal operation:
The design calculations for the various vessel components are presented in the following.
In each case, all relevant formulas and their references from EN 13445-3:2009 are given.
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5.6.1.2 Cylindrical shell
5.6.1.2.1 Required thickness
The dimensions of the selected elliptical end are standardized and come from NF E 81-103:1997 which is a French
standard currently available (see 5.6.1.3 of this report). Thus, the outside diameter of the elliptical end is 3 500 mm
and this value is used in the calculation of the required thickness of the cylindrical shell.
The required thickness e of the cylindrical shell is determined by applying 7.4.2 of EN 13445-3:2009:
P = 4,4 MPa
De = 3 500 mm
f = 184 MPa
z = 1
P ⋅ De
e= (7.4-2)
2f ⋅ z + P
4,4 × 3500
e= = 41,35 mm (7.4-2)
2 × 184 × 1 + 4,4
5.6.1.2.2 Nominal thickness
As described in 5.2.3 of EN 13445-3:2009, nominal thickness is defined by the following relation:
en = e + c + δe + δm + eex
δm , the allowance for possible thinning during manufacturing process (here rolling of the shell), is assumed to be
equal to 0.
δe is the absolute value of the possible negative tolerance on the nominal thickness and is given in the relevant
material standard, i.e. EN 10028-2:2003 which, for this subject, makes reference to EN 10028-1:2000+A1:2002:
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Extract from EN 10028-1:2000+A1:2002
Figure 31 — Abstract from EN 10028-1:2000+A1:2002
According to paragraph a) in the above extract, class B tolerances apply.
Then, EN 10029:2010 is used to determine the values of these tolerances:
Extract from EN 10029:2010
Figure 32 — Abstract from EN 10029:2010
From Table 1 of EN 10029:2010 above: δe = |- 0,3 | mm.
The resulting total for e + c + δe is:
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e + c + δe = 44,65 mm
The nominal thickness for the cylindrical shell is chosen as the nearest round value above this total:
en = e + c + δe + eex = 41,35 + 3 + |- 0,3 | + 0,25 = 45 mm
5.6.1.3 Elliptical end
It should be cost-effective for the pressure vessel manufacturer to choose a standardized end. Currently, no
European standard is available.
Therefore, the end chosen is of elliptical type according to the French standard NF E 81-103:1997 and has the
following dimensions:
De = 3 500 mm
hi = 895 mm
5.6.1.3.1 Required thickness
The required thickness e of the elliptical end is determined by applying 7.5.4 of EN 13445-3:2009.
a) Check of the condition of application of 7.5.4
7.5.4 applies only to ends for which 1,7 < K < 2,2:
K = Di /(2hi) (7.5-18)
K = 3400 /(2 x 895)=1,9 (7.5-18)
Therefore the elliptical end falls inside the field of application of 7.5.4.
b) Equivalent torispherical end
According to 7.5.4, the ellipsoidal end shall be designed as the nominally equivalent torispherical end having the
following knuckle radius r and crown radius R:
 
r = Di   0,5/K  − 0,08  (7.5-19)
  
 
 
r = 3400 ×   0,5/1,9  − 0,08  = 622,74 mm (7.5-19)
  
 
and
R = Di  0,44K + 0,02  (7.5-20)

 
R = 3400 ×  0,44 × 1,9 + 0,02  = 2910,40 mm (7.5-20)

 
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c) Required thickness of the end
The design rules for torispherical ends are given in 7.5.3 of EN 13445-3:2009
P = 4,4 MPa
Di = 3400 mm
f = 184 MPa
z = 1
R = 2 910,40 mm
r = 622,74 mm
Those dimensions fulfil three of the following conditions of applicability stated in 7.5.3.1 of EN 13445-3:2009:
r = 622,74 mm ≤ 0,2Di = 0,2 × 3400 = 680 mm
r = 622,74 mm ≥ 0,06 Di = 0,06 × 3400 = 204 mm
R = 2910,40 mm ≤ De since De = 3500 mm
The other conditions, which relate to the required thickness e and analysis thickness ea, will be checked later.
The required thickness e shall be the greatest of es, ey and eb. The calculation of es and eb is a direct one, while the
calculation of ey needs iterations.
— Calculation of thickness es:
P ⋅R
es = (7.5-1)
2f ⋅ z − 0,5P
4,4 × 2910,40
es = = 35 mm (7.5-1)
2 × 184 × 1 − 0,5 × 4,4
— Calculation of thickness ey:
β ⋅ P (0,75R + 0,2Di )
ey = (7.5-2)
f
β is a factor which is obtained through application of the calculation procedure described in 7.5.3.5 of
EN 13445-3:2009. The formulas used in this procedure (Equations (7.5-9) to (7.5-17) below) make β depend on the
thickness e of the end, which is unknown when starting the design of the end.
Thus, when entering the procedure for the time, a trial value of e has to be assumed:
— If the resulting value ey is smaller than the assumed value e, then e is sufficient.
— If the resulting value ey is greater than the assumed value e, then e is not sufficient and the procedure shall be
applied again using an increased value of e.
— To get the minimum required value for ey, the procedure shall be repeated until convergence of the iterative
process, i.e. until the resulting value equals the starting one.
The calculations given below are those which correspond to the converged solution.
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Y = min(e/R; 0,04) (7.5-9)
Y = 0,0125 (7.5-9)
(7.5-10)
Z = log10  1/ Y 
 
(7.5-10)
Z = log10  1/ 0,0125  = 1,90
 
X = r/Di (7.5-11)
X = 622,74/3400 = 0,183 (7.5-11)
1
N = 1,006 − 4 (7.5-12)
{6,2 + (90 Y ) }
1
N = 1,006 − = 0,878 (7.5-12)
{6,2 + (90 × 0,0125)4 }
The formula to be used for calculation of β depends on the value of X.
For X = 0,183, the formula which applies (7.5-16):
{
β = 10 (0,2 − X )β 0,1 + ( X − 0,1)β 0,2 } (7.5-16)
where:
β 0,1 = N ( −0,1833 Z 3 + 10383

, Z 2 − 12943
, Z + 0,837 ) (7.5-15)
β0,1 = 0,878 × ( −0,1833 × 1,903 + 1,0383 × 1,902

(7.5-15)
− 1,2943 × 1,90 + 0,837) = 0,764
and
{ , Y − 82,5Y 2 ) ; 0,5
β 0,2 = max 0,95(0,56 − 194 } (7.5-17)

 

β0,2 = max  0,95(0,56 − 1,94 × 0,0125 − 82,5 × 0,01252 ) ; 0,5  = 0,5 (7.5-17)

 

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{
β = 10 (0,2 − X )β 0,1 + ( X − 0,1)β 0,2 } (7.5-16)
β = 10(0,2 − 0,183) × 0,763 + (0,183 − 0,1) × 0,5  = 0,544 (7.5-16)

 
The thickness ey can now be determined:
β ⋅ P (0,75R + 0,2Di )
ey = (7.5-2)
f
0,544 × 4,4 ×  0,75 × 2910,40 + 0,2 × 3400 

  = 37,27 mm (7.5-2)
ey =
184
— Calculation of thickness eb:
 
 1 
 
 0,825  1,5 
  
 P  Di   (7.5-3)
eb =  0,75R + 0,2Di    
 
  111 fb r 
  
  
 
where
Rp0 ,2 /T 276
fb = = = 184 MPa (7.5-4)
1,5 1,5
 
 1 
  
0,825   1,5 
  

 4,4 3400  
eb =  0,75 × 2910,40 + 0,2 × 3400   ×  (7.5-3)

   111 × 184  622,74  
  
 
= 26,14 mm
The required thickness e is then:
e = MAX [es; ey; eb] = 37,27 mm.
This value fulfils the two conditions of applicability which relate to the thickness e stated in 7.5.3.1 of
EN 13445-3:2009:
r = 622,74 mm ≥ 2e = 2 × 37,27 = 74,54 mm

e = 37,27 mm ≤ 0,08 De = 0,08 × 3500 = 280 mm
The end is to be supplied according to the standard NF E 81-103:1997 for as-formed elliptical ends. Thus the
manufacturing tolerance δm can be taken as equal to 0.
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The standard NF E 81-103:1997 makes reference to NF E 81-100:1997 for thickness tolerance. This standard
states that for elliptical end and for a nominal thickness greater than 10 mm, the minimum thickness after forming
shall be 0,85en.
Therefore, the value given in this standard for the possible negative thickness tolerance δe is 0,15en.
So the following equation holds:
en ≥ e + c + 0,15en
which gives
e + c 37,27 + 3
en ≥ = = 47,38 mm
0,85 0,85
The nominal thickness for the elliptical end is chosen as the nearest round value above this value:
en = 48 mm
As an additional requirement, 7.5.3.4 of EN 13445-3:2009 shall be fulfilled:
The straight cylindrical flange of the end is 130 mm long.
0,2 3400 × 37,27

The length 0,2 Di ⋅ e is equal to = 71,19 mm.
Therefore the cylindrical flange of the end shall meet the requirements of 7.4.2 of EN 13445-3:2009 for cylindrical
shells.
Considering that the nominal thickness en = 48 mm calculated above for the end is greater than that of the cylinder,
and knowing that the larger negative thickness tolerance which applies to the end does not concern its cylindrical
flange (which is likely to be the thicker part of the end), it comes out that the required thickness of the flange part
will necessarily meet the requirement of 7.4.2 because made of same material as the connected shell.
Standard NF E 81-103 proposes a nominal thickness of 50 mm. This thickness is retained for the application of the
rules of EN 13445.
Then, the analysis thickness ea fulfils the condition of applicability stated in 7.5.3.1 of EN 13445-3:2009:
ea = 39,5 mm ≥ 0,001 De = 0,001× 3500 = 3,5 mm
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5.6.1.4 Nozzle
5.6.1.4.1 Required thickness (ignoring the opening)
The required thickness e of the nozzle shall be determined by using 7.4.2 of EN 13445-3:2009:
P = 4,4 MPa
De = 508 mm (DN 500)
f = 162,5 MPa
z = 1
P ⋅ De
e= (7.4-1)
2f ⋅ z + P
4,4 × 508
e= = 6,78 mm (7.4-1)
2 × 162,5 × 1 + 4,4
As described in 5.2.3 of EN 13445-3:2009, the nominal thickness is defined by the following relation:
en = e + c + δe + δm + eex
δm, the allowance for possible thinning during manufacturing process is assumed equal to 0.
To determine δe, let us assume a nominal thickness of 12,5 mm which is one of the available thicknesses
mentioned in Table 8 of EN 10216-3:2002:
The possible negative tolerance on the nominal thickness is found in the relevant material standard, i.e.
EN 10216-3:2002 which, in its 8.7, Table 9:
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For the nozzle, T/D = 12,5/508 = 0,0246. The corresponding negative tolerance is −20 % and therefore:
δe =|−0,2 x 12,5| = 2,5 mm
The resulting total for e + c + δe is:
e + c + δe = 6,78 + 3 + 2,5 = 12,28 mm
So the nominal thickness 12,5 mm initially assumed is acceptable because it assures an extra thickness of
0,22 mm:
en = e + c + δe + eex = 12,28 + 0,22 = 12,5 mm
5.6.1.5 Flange
5.6.1.5.1 Design as a Standard flange
Design of flange in Clause 11 of EN 13445-3:2009 is based on the well-known Taylor-Forge method. As a general
practice, the designers use standard flanges as far as possible. 11.4.2 of EN 13445-3:2009 allows the use of
standard flanges without calculation under some conditions which shall be all fulfilled:
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For the target vessel, all the above conditions are fulfilled so the use of standard flanges is allowed without
calculations. The justifications for each condition are presented below:
a) The flange, selected from EN 1759-1 is the following:
— Class 300 (PN 63)
— DN 500 (NPS 20)
— Type 11 (welding neck)
— Flat face.
EN 1092-1:2007 was not selected because it does not cover DN 500 for the PN 63 series.
The material group is 8E2 (P285 from EN 10222-4:1998 and see Annex B of EN 1092-1:2007).
The pressure/temperature ratings are given in Table 22 of EN 1759-1:2004. At calculation temperature (50 °C), the
maximum allowable pressure PS of the flange is equal to 51,7 bar. The calculation pressure is equal to 44 bar and
so is less than the allowable value.
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Extract form EN 1759-1:2004
b) The calculation pressure under testing conditions is the test pressure which is equal to 62,92 bar (see 7.6.3 of
this report).
The maximum allowable pressure at test temperature (20 °C) is given in Table 22 of EN 1759-1:2004 and is equal
to 51,7 bar. So the maximum test pressure permitted in 11.4.2 for design without calculation is:
1,5 x 51,7 = 77,55 bar
This is greater than the calculation pressure at test.
c) Bolt strength category shall be determined from Table 11.4-2 of EN 13445-3:2009:
From Table 4.1-1 of this report, the yield strength at calculation temperature 50 °C is 720 MPa for the bolts and
720
= 2,72
265 MPa for the flange, which gives a ratio 265 > 2,5. Therefore, bolts are classified in the "High strength"
category.
Then, the requirements that Table 11.4-1 of EN 13445-3:2009 gives for this category shall be respected to
determine the gasket:
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d) The bolt material is in agreement with the classification of bolts given in EN 1515-3:
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Extract from EN 1515-3:2005
Furthermore, the bolt material fulfils the requirements of EN 1515-4: 2009 (Table 3 Line 7 below) which is the
standard which, within its scope, confers presumption of conformity to PED 97/23/CE (see Annex ZA of
EN 1515-4:2009).
For nuts, the material is the same as for bolts and shall conform to the requirements of 11.4.3.2 of
EN 13445-3:2009.
e) The target vessel is subjected to loadings of predominantly non-cyclic nature,
f) The difference between mean temperatures of bolts and flange does not exceed 50 °C in any condition, since
transient thermal conditions are only possible between room temperature (20 °C) and calculation temperature
(50 °C), i.e. always less than 30 °C of temperature difference.
g) According to Annex O (informative) of EN 13445-3:2009 "Physical properties of steels", the coefficients of

thermal expansion at 20 °C of the bolt material (class 3.2) and of the flange material (class 1.2) are considered
as equal, because given by the same equations. Therefore the condition that they do not differ by more than
10 % is met.
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5.6.1.5.2 Selection of a gasket
EN 12560-4:2001 applies to select the gasket. The selected one is a SC/C gasket, i.e. a Self-Centering flat metal
jacketed with filler gasket. The gasket inside diameter is 540 mm and the outside diameter is 654,1 mm. The jacket
metal thickness shall be at least 0,38 mm and the filler thickness at least 1,5 mm.
Annex H (informative) of EN 13445-3:2009 gives values of the coefficients m and y to be used in case where a
calculation according to the method in 11.5 (Taylor-Forge method for narrow face bolted flanges) would be
performed.
5.6.1.6 Opening in the cylindrical shell
5.6.1.6.1 General
Clause 9 of EN 13445-3:2009 applies to design of openings in shells. For the target vessel, the opening is located
in the cylindrical shell under internal pressure. The relevant conditions of applicability are first checked and then the
opening is treated as an isolated opening.
5.6.1.6.2 Check of the conditions of applicability
According to 9.4.5 to 9.4.8 of EN 13445-3:2009, the following requirements apply:
a) Limitations on diameter:
The opening is assumed to be reinforced by a plate, so 9.4.5.2 shall apply and Equation (9.4-3) shall be checked:
d
≤ 0,5 (9.4-3)
2ris
508
= 0,15 ≤ 0,5 (9.4-3)
2 × 1708,30
where ris is derived from Equation (9.5-3):
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De
ris = − ea,s (9.5-3)
2
3500
ris = − 41,70 = 1708,30 mm (9.5-91)
2
b) As it is an opening with nozzle, condition of 9.4.5.4 shall be checked:
dib
≤1
2ris
483
= 0,14 ≤ 1
2 × 1708,30
c) As the target vessel is not submitted to fatigue or creep, 9.4.6.3 applies. Therefore the effective nozzle
thickness eb is taken as equal to the nozzle analysis thickness:
eb = ea,b
and the ratio ea,b has no limitation.

ea,s
d) For the target vessel, the nozzle is welded to the shell and is of set-in type. In this case, the weld dimensions
shall be in accordance with Tables A-6 and A-8 of Annex A of EN 13445-3:2009.
e) 9.4.8 specifies that the distance between the centreline of a shell butt-weld (longitudinal or circumferential) and
the centre of an opening shall be either less than dib / 6:
dib 494
= = 82,33 mm
6 6
or greater than the value ln given by:
ln = min (0,5 deb + 2ea,s; 0,5 deb + 40) (9.4-4)
ln = min (0,5 x 508 + 2 x 41,7; 0,5 x 508 + 40) = 294 mm (9.4-4)
5.6.1.6.3 Calculation as an isolated opening
a) General formula and associated requirements
9.5 of EN 13445-3:2009 gives all the requirements for isolated openings.
9.5.1 gives the conditions under which an opening may be considered as isolated. For the target vessel, only one
opening is taken into account, so it is considered as isolated by nature.
The reinforcing plate is manufactured from the same product as used to manufacture the cylindrical shell.
9.5.2 gives the rules for reinforcement. The general formula which applies is (9.5-7):
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(Afs + Afw) ( fs - 0,5P) + Afp (fop - 0,5P) + Afb (fob - 0,5P) ≥

(9.5-7)
P (Aps + Apb + 0,5 Apφ)
where:
fob = min (fs; fb) (9.5-8)
fop = min (fs; fp) (9.5-9)

fob = min (184; 162,5) = 162,5 MPa (9.5-8)
fop = 184 MPa (9.5-9)
For the reinforcing plate, 9.5.2.3.1 of EN 13445-3:2009 applies. The following conditions shall be fulfilled:
— reinforcing plate shall be fitted in close contact with the shell.
— the width of a reinforcing plate l'p to be considered as contributing to reinforcement is given by
' = min(l ; l )
lp (9.5-19)
so p
where:
l so = ( 2r is + e c ,s ) ⋅ e c ,s (9.5-2)
lso = (2 × 1708,30 + 41,7) × 41,7 = 379,75 mm (9.5-2)
lp is equal to 400 mm, therefore the length considered as contributing to reinforcement is:
' = min(379,75 ; 400) = 379,75 mm

lp (9.5-19)
— the value of ep used for the calculation of Afp shall not exceed the following
e p = min(ea,p ; ec,s ) (9.5-20)
e p = 41,70 mm (9.5-20)
— furthermore the analysis thickness of the reinforcing plate shall meet the following condition
ea,p ≤ 1,5 ea,s (9.5-21)
This condition is automatically fulfilled since for the target vessel ea,p = ea,s
— the stress loaded cross sectional areas of the reinforcing plate is given by the following formula (valid in all
cases, whatever the opening type):
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Af p = l p' ⋅ e p (9.5-22)
Af p = 379,75 × 41,70 = 15 835,63 mm2 (9.5-22)
b) Calculation of the stress loaded cross sectional areas and pressure loaded areas
The areas used in formula (9.5-7) shall be calculated using the appropriate formulas given in 9.5.2.4 for different
opening case.
The formulas which apply to the opening of the target vessel are those given for the case described as "Nozzle
normal to shell with a reinforcing plate".
The corresponding Clause which applies is 9.5.2.4.4.1 of EN 13445-3:2009.
Figure 9.4-9 from EN 13445-3:2009 below shows the various dimensions used to calculate the loaded areas.
NOTE Reinforcing plate is not represented here. This figure illustrates a case of a protruding nozzle with variable shell and
nozzle thickness. In the case under study, the protruding length l’bi is equal to 0 (set-in nozzle), the thicknesses are constant
and there is a reinforcing plate of same thickness as the shell.
The maximum nozzle length which can be considered as contributing to the reinforcement is:
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l bo = (d eb − eb ) ⋅ eb (9.5-76)
lbo =  508 − 7  × 7 = 59,22 mm (9.5-76)

 
The stress loaded areas are:
Afb = eb · (l’b + l’bi + e's) (9.5-78)
Afs = l s' ⋅ ec,s (9.5-79)
where:
l’b = min (lbo; lb) = min (59,22; 500) = 59,22 mm (9.5-82)
ls' = min (lso ; ls ) = min (379,75 ; 1000) = 379,75 mm (9.5-83)
Assuming that the nozzle fully penetrates the vessel wall, i.e. e's = ea,s , we get:
Afb = 7 x (59,22 + 0 + 41,7) = 706,44 mm² (9.5-78)
Afs = 379,75 × 41,7 = 15 835,63 mm2 (9.5-79)
The pressure loaded areas are:
Apb = 0,5dib·( l'b + ea,s ) (9.5-84)
Apb = 0,5 x 494 x ( 59,22 + 41,7 ) = 24 927,22 mm² (9.5-84)
Aps is determined from the rules given in 9.5.2.4.4.3 of EN 13445-3:2009:
d
a = eb (9.5-90)
2
508
a= = 254 mm (9.5-90)
2
De
ris = − ea,s (9.5-91)
2
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3500
ris = − 41,7 = 1708,30 mm (9.5-91)
2
 
lso =  (De − 2ea,s ) + ec,s  ⋅ ec,s (9.5-92)
 
lso =  (3500 − 2 × 41,7) + 41,7  × 41,7 = 379,75 mm (9.5-92)

 
l s' = min(l so ; l s ) (9.5-93)
ls' = min(379,75 ; 1000) = 379,75 mm (9.5-93)
 
Aps = ris ⋅  l s' + a  (9.5-94)
 
 
Aps = 1708,30 ×  379,75 + 254  = 1 082 637,48 mm2 (9.5-94)

 
Afp has already been obtained – see last calculation in a) above.
The welded area Afw is neglected because the nozzle is assumed to be connected to the shell by a full penetration
weld which adds only a small area to the other stress loaded cross sectional areas.
c) Check of the resistance of the opening
The required areas being calculated, inequality (9.5-7) can be checked:
(Afs + Afw) ( fs - 0,5P) + Afp (fop - 0,5P) + Afb (fob - 0,5P) ≥

(9.5-7)
P (Aps + Apb + 0,5 Apφ)
(15 835,63 + 0) x ( 184 - 0,5 x 4,4) + 15 835,63 x (184 - 0,5 x 4,4) +

(9.5-7)
706,44 x (162,5 - 0,5x4,4) ≥ 4,4 x (1 082 637,48 + 24 927,22 )
5 871 078,23 mm² ≥ 4 873 284,70 mm² (9.5-7)
Then, inequality (9.5-7) is checked, design of opening is valid.
5.6.1.6.4 Openings close to a shell discontinuity
9.7 of EN 13445-3:2009 applies to openings close to a shell discontinuity.
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For what concerns the target vessel, it is worth knowing the minimum distance the nozzle shall respect from the
end-to-shell junction to allow checking of the opening as an isolated one. The corresponding condition is described
in 9.7.2.1a)
w > wmin = max ( 0,2 ( 2r is + e c ,s ) ⋅ e c ,s ;3e a ,s ) (9.7-1)
w > wmin = max (0,2 (2 × 1708,30 + 41,7) × 41,7 ; 3 × 41,7) = 125,10 mm (9.7-1)
Referring to Figure 9.7-1 of EN 13445-3:2009, the distance w is set to 1 000 mm, so Equation (9.7-1) is verified.
5.6.1.7 Design of the shell as supported by two saddles support
5.6.1.7.1 General
16.8 of EN 13445-3:2009 gives a calculation procedure to check strength and stability of the shell. In this
procedure, two vessel regions are considered:
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— The vessel region located between the saddles where formulas 16.8-10 (strength) and 16.8-13 (instability)
shall be respected.
— The saddle supports region where formulas 16.8-27 (strength) and 16.8-28 (instability) shall be respected.
16.8.4 gives conditions to exempt from calculation but for the target vessel not all of these conditions are fulfilled.
Therefore, a complete calculation shall be performed.
5.6.1.7.2 Specifics symbols and abbreviations
The list here-below includes the specific symbols and abbreviations used in the formulas and their values to
perform calculation:
a1 = 1 000 mm is the distance from saddle support to adjacent end of cylindrical

part;
a2 = 350 mm is the distance from horn of saddle to end of reinforcing plate;
a3 = 1 596,67 mm is the length of equivalent cylindrical shell = a1 + 2 Hi / 3;
b1 = 250 mm is the axial width of saddle of saddle support;
b2 = 500 mm is the width of reinforcing plate;
Di = 3410 mm is the shell inside diameter;
E = 210 000 MPa is the modulus of elasticity of shell material at design
temperature;
ea = 41,70 mm is the analysis thickness as defined in 5.2.3 of EN 13445-3:2009;
e2 = 45 mm Is the nominal thickness of the reinforcing plate;
li = 18 260 mm is the distance between two successive saddles;
n = 2 is the number of saddles;
Hi = 895 mm is the inside height of the elliptical end;
L = 20 260 mm is the length of cylindrical part of vessel (including cylindrical part
of ends);
P = 4,4 MPa is the calculation pressure;
R = 1 727,5 mm is the mean shell radius;
W = 2 065 000 N is the total vessel weight (including content);
WF = 1 065 000 N is the fluid weight;
δ = 120° is the included angle of saddle support (in degrees);
δ2 = 140° is the included angle of reinforcing plate (in degrees);
NOTE W is the total weight of the pressure vessel including the content. To calculate W, a density of
3 3
7 900 kg/m for steel have been taken. For the content (fluid weight WF), a density of 540 kg/m have been taken
3
for normal operating load case and 1 000 kg/m for testing load case.
Figure 16.8-4 of EN 13445-3:2009 below shows the dimensions used in calculation:
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5.6.1.7.3 Check of the conditions of applicability
16.8.3 defined the conditions of applicability which are as follows:
a) 0,001 ≤ [en / Di = 45 / 3410 = 0,0132] ≤ 0,05;
0
60 ≤ δ ≤ 180;
b) If a reinforcing plate is used:
e2 ≥ en: for the target vessel, e2 = en = 45 mm
a2 ≥ 0,1 Di: for the target vessel, a2 = 350 mm ≥ 0,1 Di = 341 mm
c) The saddles are loaded vertically downwards.
d) It is preferable to weld the saddle to the vessel. However if welding is not possible, care should be taken to
ensure that the vessel is uniformly supported by the saddle.
e) If axial displacements due to thermal dilatation are to be expected, only one saddle shall be fixed to the
foundation, while the other saddles shall be free to move in axial direction. Alternatively all saddles may be
clamped if they are sufficiently designed to withstand the axial deformations.
f) Distances from saddle to any other local loads in all directions should be not less than
Di en = 3410 × 45 = 391,73 mm;
g) Type of saddle support: type A, B or C (see Figures 16.8-1 to 16.8.3);
For the target vessel, the type of saddle support is Type A, as defined in Figure 16.8-1 of EN 13445-3:2009
reproduced below:
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5.6.1.7.4 Determination of loads applied to the pressure vessel
The shell is considered as a beam of constant cross section supported by the two support saddles.
The loads which are applied to this beam have to be determined.
Figure 16.8-6 of EN 13445-3:2009 below shows the beam model which represents the pressure in the general
case (more than two saddles). In this model, the vessel is assumed as being simply supported at each saddles.
a) Weight load per unit vessel length
W
q= (16.8-1)
L+4Hi /3
2 065 000
q= = 96,26 N / mm (16.8-1)
20260 + 4 × 895 /3
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b) Weight moment at the ends of the beam
W
M0 =q F D 2 /16 (16.8-2)
W i
1 065 000
M0 = 90,75 × × 3410 2 /16 = 36 078 095,38 Nmm (16.8-2)
2 065 000
5.6.1.7.5 Determination of the forces and moments applied to the shell
For type A saddle support, the following calculations apply:
a) Forces at the saddles
W
Fi = (16.8-3)
n
2 065 000
F1 = F2 = = 1 032 500 N (16.8-3)
2
b) Moment in shell at the saddles
M1=M 2 =qa 2 / 2−M0 (16.8-4)

3
M1=M 2 =96,26 × 1596,672 / 2−36 078 095,38 = 86 616 037,88Nmm (16.8-4)
c) Shear force in shell at the saddles
L−2a1
Qi =Fi (16.8-5)
L+ 4Hi /3
20260 − 2 × 1000
Q1 = Q2 = 1 032 500 × = 878 812,15 N (16.8-5)
20260 + 4 × 895/3
d) Moment in shell between the saddles
( ) ( ) (
M 12 = M 0 + F1 . L / 2 − a1 − q / 2 . L / 2 + 2 H i / 3 )2 (16.8-6)
2
M12 = 36 078 095,38 + 1 032 500 × 20260/ 2− 1000  −  96,26/ 2 ×  20260/ 2 + 2 × 895/3 
      (16.8-6)
= 3 925 161 428,71 Nmm
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5.6.1.7.6 Load limit for the shell between the saddles
16.8.6 requires to check the load limit for the shell between the saddles if the inequality:
| moment between saddles | > | moment at saddle |
is met.
This is the case for the target vessel.
a) Strength calculation
Check of the longitudinal stresses:
P Di 4 M ij K12
+ ≤ fmax (16.8-10)
4 ea π Di2 ea
fmax = 184 MPa (see Table 5.5-1 of this report)
K12 is a coefficient given by Equation (16.8-11):
K12 = max (m; 1,0)
where m is determined by Equation (16.8-12):

-3 -6
m = 1,6 - 0,20924 (x -1) + 0,028702 x (x - 1) + 0,4795.10 y (x -1) - 0,2391.10 xy (x -1)
-2 -6 -6
- 0,29936.10 (x -1) x2 - 0,85692.10 (x -1) y2 + 0,88174.10 x2 (x -1) y
-8 -4 -9
- 0,75955.10 y2 (x -1) x + 0,82748.10 (x -1) x3 + 0,48168.10 (x -1) y3
with x = L / Di and y = Di / ea
Therefore, K12 = 1,16
4 × 3 925 161 428,71 × 1,16

4,4 × 3410 (16.8-10)
+ = 101,92 ≤ 184 MPa
4 × 41,7 π × 3410 2 × 41,7
So the longitudinal stress is acceptable.
b) Instability check (with P = 0)
Then the instability shall be checked using condition 16.8-13:
M12 /M max ≤ 1,0 (16.8-13)
Mmax is the allowable global moment determined according to 16.14 of EN 13445-3:2009.
π
Mmax = D 2 ⋅ ea ⋅ σ c,all (16.14-3)
4
σc,all is the maximum permitted compressive longitudinal stress determined using the procedure given in 16.14.8 of
EN 13445-3:2009.
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w
This calculation is allowed if the maximum value of l (tolerances) does not exceed 0,02, where w is the deviation
from the perfect shape and l is the length of the template for checking the shape deviations.
l is determined from 16.14.8.2 and is illustrated by Figure 16.14-1 reproduced below:
Then:
1,21E ⋅ ea
K = (16.14-15)
σ e⋅ D
1,21 × 210000 × ⋅41,7

K= = 11,11 (16.14-15)
276 × 3455
As D/ea = 3455 / 41,7 = 82,85 ≤ 424, according to point 2) of 16.14.8.1 α is given by:
0,83
α= (16.14-16)
10
, + 0,005 D / e α
0,83
α= = 0,70
1,0 + 0,005 × 3455 / 41,7 (16.14-16)
 
w  1,5 − 50 w 
 l 
If the maximum value of l lies between 0,01 and 0,02 the value of α is reduced by the factor  .
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w
= 0,02
One assumes that l , then α shall be reduced by the factor 1,5 − 50 × 0,02 = 0,5 .
Therefore, α = 0,70 × 0,5 = 0,35 .
As αK = 0,35 x 11,11 = 3,88 ≥ 0,5, according to point 4) of 16.14.8.1 Δ is given by:
0.4123
10
, −
(α K ) 0.6 (16.14-19)
∆=
15
,
0.4123
1,0 −
0.6
 3,88  (16.14-19)
 
∆=   = 0,54
1,5
The maximum allowable compressive stress is:
σ c,all = σ e ∆ (16.14-20)
with σe = 276 MPa (see Table 4.1-1 of this report)
σ c,all = 276 × 0,54 = 149,04 MPa (16.14-20)
and the allowable global moment Mmax is:
π
M max = D 2 ⋅ ea ⋅ σ c,all (16.14-3)
4
π
Mmax = × 34552× 41,7 × 149,04 = 58 782 271 278,97 Nmm (16.14-3)
4
We obtain:
3 925 161 428,71

M12 /Mmax = = 0,07 ≤ 1,0 (16.8-13)
58 782 271 278,97
So condition 16.8-13 is met and the stability of the shell is insured.
5.6.1.7.7 Load limit at a saddle with additional reinforcing plate
Once the load limit for the shell between saddles has been checked, and since it is a Type A saddles configuration,
load limits at one saddle shall be verified. The load limits shall be checked at locations 2 and 3 of the shell wall as
shown in Figure 16.8-4 of EN 13445-3:2009.
The procedure described in 16.8.8 of EN 13445-3:2009 applies.
If condition 16.8-32 below is not met, then two distinct calculations shall be performed using 16.8.7 of
EN 13445-3:2009:
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b2 ≥ K11Di + 1,5b1 (16.8-32)
where K11 is given by Equation (16.8-33):
5
K11 =
 0,10472 δ  Di (16.8-33)
 3
  ea
5
K11 = = 0,09
 0,10472 × 120  3410 (16.8-33)
 3
  41,70
We get:
K11Di + 1,5b1 = 0,09 × 3410 + 1,5 × 250 = 687,59 mm
Since b2 = 500 mm, condition 16.8-32 is not met.
Therefore, 16.8.7 of EN 13445-3:2009 shall apply by performing two calculations, referred to as Calculation 1 and
Calculation 2.
5.6.1.7.8 Load limit at the saddle without a reinforcing plate (Clause 16.8.7)
a) Calculation 1
The reinforcing plate is considered as a saddle of width b2 and of angle δ2 instead of b1 and δ. The wall thickness
of the shell is ea, while the thickness of the reinforcing plate is not considered.
1 - Calculation of parameters γ and β and factors K3 to K10:
- Parameter γ
γ =2,83  a1/Di  ea /Di (16.8-15)

 
γ = 2,83 ×  1000 / 3410  × 41,7 / 3410 = 0,09 (16.8-15)

 
- Parameter β
b = 0,91 b2 / Di ea (16.8-16)
β = 0,91× 500 / 3410 × 41,7 = 1,21 (16.8-16)
- Factor K3
(
K 3 = max 2,718282 − β sin β / β ; 0,25 ) (16.8-17)
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 
K 3 =max 2,718282−1,21 sin 1,21 / 1,21 ; 0,25  = 0,25 (16.8-17)
 
 
- Factor K4
(
K 4 = 1 − 2,718282 − β cos β / β ) (16.8-18)
 
K 4 = 1−2,718282 −1,21 cos 1,21 / 1,21 = 0,740 (16.8-18)
 
 
- Factor K5
1,15−0,0025 δ 2
K5 =
(16.8-19)
sin 0,5 δ 2 
 
1,15 − 0,0025 × 140

K5 = = 0,851
(16.8-19)
sin 0,5 × (140 π ) / 180 
 
- Factor K6
max 1,7 − 0,011667δ 2 ; 0 

K6 =  
(16.8-20)
 
sin 0,5 δ 2 
 
max  1,7 − 0,011667 × 140 ; 0 

  = 0,071
K6 = (16.8-20)
 
sin  0,5 × (140π ) / 180 
 
- Factor K7
1,45−0,007505 δ 2
K7 =
sin  0,5 δ 2  (16.8-21)
 
1,45 − 0,007505 × 140

K7 = = 0,425
sin  0,5 × (140π ) / 180  (16.8-21)
 
- Factor K8
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 
 0,8 γ +6γ 
K8 = min 1,0;  (16.8-22)
 0,017453 δ 2 
 
 
 
 0,8 0,09 + 6 × 0,09 
K8 = min 1,0 ;  = 0,325 (16.8-22)
 0,017453 × 140 
 
 
- Factor K9
0,65 60
K9 = 1−
2 δ2 (16.8-23)
1 +  6γ 
 
0,65 60
K = 1− × = 0,673
9 2 140 (16.8-23)
1 +  6 × 0,09 
 
- Factor K10
1
K10 =
Di b2 (16.8-24)
1 + 0,010472 3 δ2
ea Di
1
K10 = = 0,517
3410 500 (16.8-24)
1 + 0,010472 × 3 × × 140
41,7 3410
2 - Calculation of ratio υ1, υ2,1 and υ2,2:
Table 16.8-1 from EN 13445-3:2009 is reproduced below:
P=0 P = Design pressure

Location υ1
υ2,1 υ2,2
K 6 K8 4 Mi 1  P Di 4 Mi  1
− 0,23 −  
2
K5 K3 π Di2 ea K 2 f 4e − 
 a π Di2 ea  K 2 f
K4 0 P Di 1
−0,53
3
K 7 K 9 K10 sin 0,5 δ 2  2 ea K 2 f
 
From 16.6.6, K2 = 1,25 for design conditions (normal operating load case).
The results are shown in Table 5.6.1.7.8-1 of this report.
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3 - Calculation of K1, σb,all,2, σb,all,3, F2,max and F3,max
The factor K1 shall be determined in order to perform the calculation of the limit bending stress σb,all,2 and σb,all,3 for
the locations 2 and 3.
These limit bending stresses allow the determination of the maximum allowable saddle loads F2,max and F3,max.
16.6.6 of EN 13445-3:2009 gives the Equation (16.6-7) to determine K1:
1 − υ 22
K1 =
2 (16.6-7)
1 
 + υ1 υ 2  +
3 
1 
 + υ1 υ 2 
3  ( )
+ 1 − υ 22 υ12
16.6.6 of EN 13445-3:2009 gives the formula for the limit bending stress:
σ b,all = K1 K2 f (16.6-6)
The maximum allowable saddle load F2,max at location 2 is given by:
0,7 σ b,all,2 Di ea .ea

F2,max = (16.8-25)
K3 K5
The maximum allowable saddle load F3,max at location 3 is given by:
0,9 σ b,all,3 Di ea .ea

F3,max = (16.8-26)
K 7 K 9 K10
Results for K1, σb,all,2, σb,all,3, F2,max and F3,max are shown in Table 5.6.1.7.8-2 of this report.
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Table 5.6.1.7.8-1
P=0 P = Design pressure

Location υ1
υ2,1 υ2,2
4 × 86 616 037,88 1  
0,071× 0,325 − ×  4,4 × 3410 4 × 86 616 037,88 
− 0,23 × = − 0,0248 2 1,25 × 184 1
2 π × 3410 × 41,70  − × = 0,39
0,851 × 0,25  4 × 41,70 2
π × 3410 × 41,70  1,25 × 184
= − 0,0009888  
0,748
−0,53 ×
0,425 × 0,673 × 0,517 × sin  0,5 × (140π ) / 180  4,4 × 3410 1
3   0 × = 0,782
2 × 41,70 1,25 × 184
= − 2,82
Table 5.6.1.7.8-2
Location P=0 P = Design pressure

K1 1,497 1,308
1,497 × 1,25 × 184 = 344,49 MPa 1,308 × 1,25 × 184 = 300,89 MPa
σb,all,2
2 σb,all,2 = MIN(344,49; 300,89) = 300,89 MPa
0,7 × 300,89 × 3410 × 41,70 × 41,70

F2,max F2,max = = 15 561 054,50 N
0,25 × 0,851
K1 0,315 0,558
0,315 × 1,25 × 184 = 72,47 MPa 0,555 × 1,25 × 184 = 128,38 MPa
σb,all,3
3 σb,all,3 = MIN(72,47; 128,38) = 72,47 MPa
0,9 × 72,47 × 3410 × 41,70 × 41,70

F3,max F3,max = = 6 927 403 N
0,425 × 0,672 × 0,517
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4 - Maximum allowable load at saddle
 
Fi ≤ min  F2,max ; F3,max  (16.8-27)
 
1 032 500 N ≤ 6 927 403 N (16.8-27)
Therefore, the force Fi (i = 1,2) on the saddle is acceptable.
5 - Instability check
Condition 16.8-28 shall be met:
2
∣P∣/Pmax +∣Mi∣/Mmax + Feq / Fmax + (Qi / Qmax) ≤ 1,0 (16.8-28)
Pmax = 0 since there is no external pressure.
Mmax has been calculated in 5.6.1.7.6b) of this report.
Feq is given by Equation (16.8-29):
π Di
Feq = Fi K 6 K8 (16.8-29)
4 ea
Feq = 1 032 500 ×

π × 3410 × 0,071 × 0,325 = 168 726,97 N
4 41,70 (16.8-29)
Fmax is given by formula 16.14-2:
Fc,max =π D⋅ ea ⋅ σ c,all (16.14-2)
Fc,max =π × 3455 × 41,70 × 149,04 = 68 054 727,96 N (16.14-2)
σc,all has been calculated in 5.6.1.7.6b) of this report.
L R
≤ 8,7
R ea
Qmax shall be calculated from Equation (16.8-30) as the condition is met:
125
,
e 
0,75 π R e a E  a 
R R e  
3 15
.
 R
Qmax = 1 + 42    a   (16.8-30)
15
, L  L  R  
 
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1,25
 
 41,70 
0,75π × 1727,5 × 41,70 × 210 000 × 
 1727,5 
Qmax =  
1,5
 1.5  (16.8-30)
 3  
1727,5   
1727,5   41,70  
× 1 + 42
20260   20260   1727,5  
     
 
= 66 023 917,87 N
Therefore, condition 16.8-28 is met and the shell stability is insured:
2
∣P∣/Pmax +∣Mi∣/Mmax + Feq / Fmax + (Qi / Qmax) ≤ 1,0 (16.8-28)
b) Calculation 2
The reinforcing plate is considered as a reinforcement to the vessel wall. The saddle is considered as of width b1
and of angle δ, while the true shell thickness is replaced by a combined thickness ec:
 2 
 f 
  2 
ec = ea2 + e 2 . min  1 ;  f   (16.8-35)
2
   
 
 
Where:
f = f2 = 184 MPa (since the material of reinforcing plate is the same as the one of cylindrical shell, see
Table 5.5-1 of this report),
then:
ec = 41,72 + 452 = 61,35 mm (16.8-35)
The procedure shown in § 5.6.1.7.8 a) (Calculation 1) of this report shall be repeated with these new parameters:
b1, δ and ec.
The corresponding calculations are not reported here. They show that all the requirements for strength
(Equation (16.8-10)) and instability (Equation (16.8-13)) are fulfilled for the shell between the saddles, as well as all
the requirements for strength (Equation (16.8-27)) and instability (Equation (16.8-28)) for the shell at saddles.
5.6.2 Testing load case
5.6.2.1 General
For the target vessel, the test pressure Pt is equal to 62,92 bar or 6,292 MPa (see 7.6.3 of this report).
5.3.2.3 of EN 13445-3:2009 defines load cases for final assessment:
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In testing conditions, the following requirement given in 10.2.3.3.1a) of EN 13445-5:2009 shall be fulfilled:
Then, the maximum permissible pressure Pmax shall be determined for each component of the target vessel and for
its opening. The smallest of these Pmax values shall be greater than the pressure test Pt.
5.6.2.2 Maximum permissible pressure of the cylindrical shell
The maximum permissible pressure Pmax of the cylindrical shell is determined by applying 7.4.2 of
EN 13445-3:2009:
D = 3455 mm
ea = 41,7 mm
ftest = 271,43 MPa
z = 1
2 ⋅ ftest ⋅ z ⋅ ea
Pmax = (7.4-3)
D
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2 × 271,43 × 1 × 41,7
Pmax = = 6,55 MPa (7.4-3)
3455
The maximum permissible pressure is not exceeded at test, so the shell fulfils the requirement of 10.2.3.3.1a) of
EN 13445-5:2009.
5.6.2.3 Maximum permissible pressure of the elliptical end
The maximum permissible pressure Pmax of the elliptical end is determined by applying 7.5.3.3 of
EN 13445-3:2009:
Di = 3 400 mm
ea = 39,5 mm (Tolerance is 15 % of nominal thickness as specified by standard
NF E 81-103:1997, see 5.6.1.3.2 of this report)
ftest = 271,43 MPa
R = 2 910,40 mm
r = 622,74 mm
z = 1
Pmax shall be the least of Ps, Py and Pb:
2ftest ⋅ z ⋅ ea
Ps = (7.5-6)
R + 0,5ea
2 × 271,43 × 1 × 39,5
Ps = = 7,32 MPa (7.5-6)
2910,40 + 0,5 × 39,5
ftest ⋅ ea
Py = (7.5-7)
β (0,75R + 0,2Di )
With β = 0,543 replacing e by ea:
271,43 × 39,5
Py = = 6,898 MPa (7.5-7)
0,543 × (0,75 × 2910,40 + 0,2 × 3400)
1,5 0,825
   
 ea  r  (7.5-8)
Pb = 111 ftest    D 
 0,75R + 0,2Dι i
   
1,5 0,825
   622,74 
 39,5   
Pb = 111 × 271,43 ×
 0,75 × 2910,40 + 0,2 × 3400   3400  (7.5-8)
   
= 12,04 MPa
Therefore, Pmax = Min [Ps; Py; Pb] = Py = 68,98 bar
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The maximum permissible pressure is not exceeded at test, so the elliptical end fulfils the requirement of
10.2.3.3.1a) of EN 13445-5:2009.
5.6.2.4 Maximum permissible pressure of the nozzle
The maximum permissible pressure Pmax of the nozzle is determined by applying 7.4.2 of EN 13445-3:2009:
D = 495,5 mm
ea = 7 mm
ftest = 261,90 MPa
z = 1
2 ⋅ ftest ⋅ z ⋅ ea
Pmax = (7.4-3)
D
2 × 261,90 × 1 × 7
Pmax = = 11,02 MPa (7.4-3)
495,5
The maximum permissible pressure is not exceeded at test, so the nozzle fulfils the requirement of 10.2.3.3.1a) of
EN 13445-5:2009.
5.6.2.5 Maximum permissible pressure of the flange
As specified in 10.2.3.3.1a) of EN 13445-5:2009 (see also 7.6.3 of this report):
Since the flange has been selected and checked according to the rules given in 11.4.2 of EN 13445-3:2009 for use
of standard flange without calculation (see 5.6.1.5 of this report), no Pmax value needs to be calculated.
When clause 11.4.2 is used, the condition to be checked at test is that Pt is lower than the maximum pressure to
which the flange may be subjected at test, as defined in 11.4.2 b) of EN 13445-3:2009. This pressure has been
calculated at 5.6.1.5.1 b) of this report and is equal to 77,55 bar or 7,755 MPa.
The maximum pressure permitted at test is not exceeded, so the flange requirement of 10.2.3.3.1a) of
EN 13445-5:2009 is fulfilled.
5.6.2.6 Maximum permissible pressure of the opening
The maximum permissible pressure Pmax for the opening is determined by applying Equation (9.5-10) of 9.5.2.1.2 of
EN 13445-3:2009, using the appropriate ftest value for each nominal design stress:
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( Af s + Af w ) ⋅ f + Af b ⋅ f ob + Af p ⋅ f op
Pmax = s
(9.5-10)
( Ap s + Ap b + 0,5Ap ) + 0,5 ( Af s + Af w + Af b + Af p )
ϕ
(15 835,63 + 0) × 271,43 + 706,44 × 261,90 + 15 835,63 × 271,43

P =
max (1 082 637,48 + 24 927,22 + 0 ) + 0,5 × (15 835,63 + 0 + 706,44 + 15 835,63) (9.5-10)
= 7,81 MPa
The maximum permissible pressure is not exceeded at test, so the opening fulfils the requirement of 10.2.3.3.1a) of
EN 13445-5:2009.
5.6.2.7 Verification of the shell supported by two saddles support during hydrostatic test
For design of the shell supported by two saddles support in testing conditions, the same calculation procedure
presented in 5.6.1.7 of this report shall be performed with the following modifications:
— the calculation pressure shall be replaced by the test pressure (see 7.6.3 of this report),
— the allowable design stress fd shall be replaced by ftest (see Table 5.5-1 of this report),
— the factor K2 (Equation (16.6-6)) shall be equal to 1,05,

3
— the fluid weight WF shall be determined with a density of 1 000 kg/m (water).
— the safety factor in Equation (16.14-18) or (16.14-19) (i.e. 1,5 in the nominator) for the calculation of coefficient
Δ should be adjusted to a value corresponding to the testing load case (i.e. 1,05, see Clause 6 of EN 13445-
3:2009)
The corresponding calculations are not reported here. They show that at hydrostatic test, all the requirements for
strength (Equation (16.8-10)) and instability (Equation (16.8-13)) are fulfilled for the shell between the saddles
during hydrostatic test, as well as all the requirements for strength (Equation (16.8-27)) and instability
(Equation (16.8-28)) for the shell at saddles.
6 Fabrication
6.1 General
EN 13445-4:2009 gives the minimum requirements to fulfil concerning fabrication. These requirements concerned
especially:
— The materials, for traceability and marking
— Manufacturing tolerances
— Welding (Welding Procedure Specification (WPS), qualification of WPS, qualification of welders and welding
operators, etc.) and Post Weld Heat Treatment
— Production tests
— Forming of pressure parts
— Repairs and finishing operations
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6.2 Minimum requirements for fabrication
6.2.1 Materials
Material traceability shall be ensured by the pressure vessel manufacturer. Requirements of 4.2 of
EN 13445-4:2009 shall be fulfilled. 6.3 of EN 13445-5:2009 and 4.4 of EN 13445-2:2009 shall also be fulfilled.
6.2.2 Tolerances
16.14.8.1 of EN 13445-3:2009 shall be applied to verify the resistance of the shell supported by two saddles
support. This Clause requires tolerances to allow the use of the design rules, see 5.6.1.7.6b) of this report.
5.2 of EN 13445-4:2009 gives requirements on the misalignment of middle lines for longitudinal welds. For the
cylindrical shell, the maximum misalignment d1 is given by Table 5.2-1 of EN 13445-4:2009:
The nominal thickness of the cylindrical shell is 45 mm (see 5.6.1.2 of this report). Thus, the maximum
misalignment d1 is, for 30 < e1 ≤ 120:
e 45
d1 = 1 + 2 = + 2 = 3,5 mm
30 30
For circumferential welds, the maximum misalignment d1 is derived by applying the requirements of Table 5.2-3 of
EN 13445-4:2009:
Thus, the maximum misalignment d1 is, for 30 < e1 ≤ 150:
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e 45
d1 = 1 + 3 = + 3 = 4,5 mm
30 30
Requirements are also given in 5.3 of EN 13445-4:2009 for surface alignment.
5.4 of EN 13445-4:2009 gives requirements for vessels subjected to internal pressure:
— Tolerances on external diameter
— Out of roundness
— Deviation from the longitudinal axis
— Irregularities in profile: local irregularities in vessel profile and peaking on longitudinal butt welds
The maximum permitted peaking P is 5 mm by applying the requirements of Table 5.4-2 of EN 13445-4:2009:
Finally, 5.4.5 of EN 13445-4:2009 gives the requirements to limit local areas of thickness below the required
thickness and 5.4.6 gives the tolerances for dished end.
For structural tolerances, values recommended in Annex A (informative) of EN 13445-4:2009 should not be
exceeded.
6.2.3 Procedures for welding
Welding of the components shall be undertaken when all of the conditions below are fulfilled (7.1 of
EN 13445-4:2009):
— Welding procedure specifications (WPS) are held by the manufacturer according to EN ISO 15609:2004
— WPS is qualified according to EN ISO 15614-1:2004 or by preproduction tests according to

EN ISO 15613:2004, with the additional requirements:
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and
Moreover, B.4 of Annex B of EN 13445-2:2009 shall also apply. The required TKV for WPAR is determined from the
requirements of Annex B of EN 13445-2:2009 (see 4.5 of this report).
— Welders are qualified in accordance with EN 287-1:2004 and welding operators are qualified in accordance
with EN 1418:1997.
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6.2.4 Welding consumables
7.5 of EN 13445-4:2009 gives the requirements concerning the welding consumables:
4.3.5 of EN 13445-2:2009 also applies:
Requirement of Annex I paragraph 4.2b) of PED shall not apply to welding consumables. In other words, welding
consumables should not comply with harmonized standards, European approvals of materials or particular material
appraisal (see also Guideline 7/12).
The rules given in 4.4 of this report for the type of material certificate should apply to welding consumables.
NOTE If a material certificate of type 3.1 following EN 10204:2004 is required for filler material, in most cases, material
producers perform specific control on chemistry and non-specific control on mechanical characteristics.
6.3 Production tests
6.3.1 Number of production test plates
Production test shall be welded and tested in accordance with 8.2 and 8.3 of EN 13445-4:2009 defined the criteria
to determine the number of test plates.
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The number of test plates is specified in 8.2 d):
Since the testing group is 1b, the joint coefficient is equal to 1 as defined in EN 13345-5:2009, 6.6 and Table 6.6.1
(see also 7.4.2 of this report).
The following requirement of 8.2 d) shall also apply:
6.3.2 Test on production test plate
The extent of testing is specified in 8.3, and the type and number of specimens shall be in accordance with
Table 8.3-1:
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Test specimens and the relevant test specification are specified in Table 8.3.2:
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Moreover, impact test shall be carried out in accordance with the requirements of 8.2 a):
Performance of tests and acceptance criteria are specified in 8.4:
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Retests can be performed where individual tests do not conform to the requirements of 8.4. Requirements for
retests are specified in 8.4.9.
A test report shall be prepared in accordance with 8.4.10.
6.4 Forming of shell
6.4.1 General
Cylindrical shell and elliptical end are the two components which should be formed. It is recommended to cold form
components if manufacturing tools allow it according to the thickness of the component. Nevertheless, components
can be hot formed.
The two ways are presented, i.e. cold forming and hot forming.
6.4.2 Cold forming
6.4.2.1 Calculation of deformation F
6.4.2.1.1 Cylindrical shell
9.2.2 of EN 13445-4:2009 gives the requirements for the cold forming of a cylindrical shell. Equation (9.2-2) allows
the calculation of the deformation F after cold forming.
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6.4.2.1.2 Elliptical end
9.2.1 of EN 13445-4:2009 gives the requirements for the cold forming of ends. Equation (9.2-1) allows the
calculation of the deformation F after cold forming.
6.4.2.1.3 Cold forming procedure
9.3 of EN 13445-4:2009 reproduced below gives the requirements to fulfil during cold forming for material
group 1.2.
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6.4.2.2 Heat treatment after cold forming
Heat treatment after cold forming is a function of the deformation F determined in 9.2.1 and in 9.2.2 of
EN 13445-4:2009 and the material group. Necessity to heat treat after cold forming is described in 9.4.2 and in
Table 9.4-1 of EN 13445-4:2009.
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6.4.3 Hot forming
6.4.3.1 General
9.3.2 of EN 13445-4:2009 gives the requirements when hot forming is performed. These requirements cover:
— The procedure for hot forming
— The necessity and the kind of heat treatment to carry out after forming
— The necessity of mechanical tests, the kind of tests and the results to reach
6.4.3.2 Hot forming procedure
9.3.2.1 of EN 13445-4:2009 gives general requirements for hot forming.
Since the heat treatment of plate is normalizing, requirements of 9.3.2.2 of EN 13445-4:2009 shall apply.
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6.4.3.3 Heat treatment after hot forming
9.4.5 of EN 13445-4:2009 gives the requirements for heat treatment after hot forming. This one shall be carried out
in accordance with Table 9.4-3 of EN 13445-4:2009 reproduced below:
For material group 1.2 requirements of 9.3.2.2 of EN 13445-4:2009 shall be fulfilled. Moreover, 9.4.1 states that
heat treatment after hot forming shall be carried out in accordance with the requirements given in the material
specification.
6.4.4 Tests after forming
6.4.4.1 General
When heat treatment is performed after cold forming or after hot forming, conformity to the material specification
shall be checked by means of mechanical tests. 9.5 and 9.6 of EN 13445-4:2009 give the minimum requirements
to fulfil for determination of batch testing and mechanical tests to perform.
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6.4.4.2 Necessity of tests
9.5 of EN 13445-4:2009 specifies when tests shall be performed or not. 9.5.1 states clearly that if heat treatment is
not required after cold forming, so, no mechanical tests are required.
9.5.2 states clearly that if heat treatment is required after cold forming or after hot forming, mechanical tests shall
be carried out. This clause specifies how to take test coupons and the required number of tests coupons.
6.4.4.3 Performance of tests
9.6 specifies:
— The kind of mechanical tests (one tensile test and three impact test)
— The acceptance criteria: results shall conform to the requirements of base material specification
— The way to perform retests when first tests failed
NOTE Hardness test is not applicable to material group 1.2
6.4.5 Inspection, marking and documentation
9.7 of EN 13445-4:2009 specifies the requirement to fulfil for inspection of formed parts: visual examination and
dimensional check. The results shall be documented.
9.8 specifies the requirements for marking and especially for the traceability of the base material and the link
between test coupon, the results of test and the corresponding formed part.
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9.9 specifies the requirements for the content of the documentation attached to the formed part.
6.5 Post weld heat-treatment (PWHT)
6.5.1 General
Requirements of Clause 10 of EN 13445-4:2009 shall apply. PWHT is not performed up to a fixed thickness and if
operating conditions do not need it (e.g. stress corrosion cracking). Necessity of PWHT depends also on the
grades of steel.
10.1 gives general requirements and specially:
6.5.2 Heat treatment conditions
6.5.2.1 PWHT procedures
Heat treatment conditions are given in 10.2, by applying requirements of Table 10.1-1:
Therefore, the welded joints between cylindrical shell and elliptical ends are subjected to PWHT.
The longitudinal seams and the circumferential seams in cylindrical shell shall also be subjected to PWHT.
Heat treatment temperature shall be between 550 °C and 600 °C, holding time for the components shall be about
45 min (en - 5) and Hollomon-Jaffe value shall not exceed 17,5. Requirements about heating rate and cooling rate
shall also be fulfilled (see 6.5.2.3 of this report).
For welded joints connecting parts which differ in thickness, 10.2.2 of EN 13445-4:2009 gives requirements to
define the thickness to be used for PWHT.
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Nevertheless, the welded joint for the connection between the nozzle and the cylindrical shell shall be subjected to
PWHT.
6.5.2.2 Method of PWHT
10.3 of EN 13445-4:2009 gives detailed requirements to perform the post weld heat treatment. The pressure
vessel, wherever possible, shall be heat treated as a whole in an enclosed furnace. If it is impossible, the pressure
vessel could be heat treated in sections in an enclosed furnace. Circumferentially welds could be heat treated
locally.
For the last two cases, requirements are given for the width of thermal insulation and heated band.
6.5.2.3 PWHT procedure
10.4 of EN 13445-4:2009 gives requirements for variation in temperature throughout the pressure vessel, the
furnace atmosphere, the use of thermocouples, etc.
If post weld heat treatment is performed in a furnace, the temperature of the furnace at the time when pressure
vessel is placed in or taken out of the furnace shall not exceed 400 °C.
The rate for heating or cooling of the pressure vessel shall not exceed 120 °C/hr (5500 / en °C/hr, en is the nominal
thickness).
6.5.3 Mechanical properties after heat treatment
Hollomon-Jaffe value shall be derived from Equation (10.1-1):
Ts = 600 + 273 = 873 K
t = 0,67 hr (40 min)
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P (600°C ) = 873 ×  log 0,67 + 20  × 10 −3 = 17,31

 
If value of Holloman-Jaffe parameter exceeds 17,5, requirements of 10.5.2 shall apply:
6.6 Others requirements
6.6.1 Repairs
Clause 11 of EN 13445-4:2009 gives the requirements that shall be fulfilled for repairs of surface defects in the
base material (11.1) and repair of weld defect (11.2).
6.6.2 Finishing
Requirements for finishing operations are given by Clause 12 of EN 13445-4:2009 where it specifies finishing after
pressure test and before shipment or transport.
7 Inspection and testing
7.1 General
EN 13445-5:2009 gives the minimum requirements to fulfil concerning inspection and testing. These requirements
concerned especially:
— The technical documentation
— Choice and extent of NDT (Non Destructive Testing)
— Calibration
— Final assessment
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— Marking
— Shipping
7.2 Performance of inspection and testing
Inspection shall be performed during fabrication and after fabrication. Inspection shall be done to ensure that all the
requirements of EN 13445 are fulfilled. Clause 4 of EN 13445-5:2009 gives requirements about inspection.
7.3 Technical documentation
The pressure vessel manufacturer shall comply with the requirements of Clause 5 of EN 13445-5: 2009 concerning
the content of the technical documentation and which type of documents is mandatory. Furthermore, as stated in
5.3, a design review shall be conducted in all cases.
7.4 Inspection and testing during fabrication
7.4.1 General
Inspection and testing shall be the responsibility of the pressure vessel manufacturer. Clause 6 of
EN 13445-5:2009 described the requirements to fulfil. Some of these requirements are enumerated below:
— Material traceability
— Visual inspection of joint preparation
— Inspection of vessel supports
— Verification of welder and welding qualification
— Destructive testing: identification and validation of test coupons, mechanical testing, preparation or certification
of test reports shall be witnessed
— Heat treatment: shall be performed in accordance with written procedures and verified by inspection.
NDT (except for visual inspection) shall be performed by a personnel qualified and certified in accordance with
EN 473:2008 (see 6.6.3.7 of EN 13445-5:2009). All NDT shall be performed in accordance with written procedures
(see 6.6.7 of EN 13445-5:2009).
NOTE EN 473:2008 is replaced by EN ISO 9712:2012.
7.4.2 Choice of testing group
The calculation derived a maximum nominal thickness of 45 mm for cylindrical shell and 50 mm for elliptical end
(see 5.6.1.2 and 5.6.1.3 of this report). Therefore, testing group, as defined by EN 13345-5:2009 6.6 and
Table 6.6.1-1 is 1b. Indeed, the main pressure-bearing parts (cylindrical shell and elliptic end) fulfilled the
requirements of this testing group:
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7.4.3 Extent of NDT
Clause 6 of EN 13445-5:2009 describes the inspection and testing requirements which shall be fulfilled. 6.6 gives
the requirements for non-destructive testing (NDT) of welded joints and 6.7 gives the requirements for destructive
testing.
Visual inspection is mandatory before performance of any surface or volumetric control, as stated in 6.6.3.1. After
that, NDT extent is described in 6.6.1.
NDT extent is a function of:
— Testing group: 1b for the target vessel as described in 7.4.2 of this report
— Type of weld: Figure 6.6.2-3 of EN 13445-5:2009, reproduced below, shows how to determine the type of weld
According to Figure 6.6.2-3, for the target vessel, types of weld are defined as to be of type 1, 2a, 3a and 15.
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The NDT extent is then determined from Table 6.6.2-1 of EN 13445-5:2009. This table gives a percentage value
applied to the total length of the welded joint.
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Figure 87 a) — Abstract from EN 13445-5:2009
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Figure 87b) — Abstract from EN 13445-5:2009
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7.4.4 Acceptance criteria
6.6.3.2 gives, depending on the NDT methods applied, the standard referring to the techniques, the
characterization and the acceptance criteria summarize in Table 6.6.3-1 of EN 13445-5:2009:
It is also important to insist on the fact that Table 6.6.4-1 of EN 13445-5:2009 shall apply for radiography
acceptance criteria.
7.4.5 Selection of NDT method
7.4.5.1 Selection of NDT method for detection of internal flaws
The choice of NDT methods shall fulfil the requirements of 6.6.3.3 of EN 13445-5:2009 and selection of NDT
methods is specified in Table 6.6.3-2 of EN 13445-5:2009:
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7.4.5.2 Selection of NDT method for detection of surface flaws
6.6.3.4 of EN 13445-5:2009 requires using the magnetic particle method (MT) since the material is a ferritic steel.
7.4.5.3 Performance of NDT
Although NDT shall be conducted according to written procedures (see 6.6.7 of EN 13445-5:2009), some
requirements are given about surface condition and preparation in 6.6.3.4 of EN 13445-5:2009.
NDT shall be carried out after post weld heat treatment (PWHT) and before proof test. For materials which are not
sensitive to reheat cracking, NDT may be performed before PWHT. It may not be the case of material group 1.2.
6.6.6 gives requirements for non-destructive retesting.
7.5 Others requirements
Others requirements for subcontracted elements (Clause 7 of EN 13445-5:2009), for miscellaneous tests (Clause 8
of EN 13445-5:2009) and for calibration (Clause 9 of EN 13445-5:2009) shall be fulfilled if necessary.
7.6 Final assessment
7.6.1 General
Final assessment is mandatory and is well described in 10.1 of EN 13445-5:2009 which is partially reproduced
below:
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7.6.2 Extent of final assessment
10.2 of EN 13445-5:2009 gives the requirements for the extent of final assessment which is structured in various
stages:
— Visual and dimensional inspection
— Review of documentation
— Proof test
7.6.3 Determination of the test pressure Pt
10.2.3.3 of EN 13445-5:2009 gives the requirements for the standard hydrostatic test.
10.2.3.3.1a) gives the way to determine the test pressure
fa and fTd are defined as follows:
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fa
f Td
As regards the value of the ratio , a requirement of 10.2.3.3.1 states:
fa
f Td
Therefore, for the target vessel, the ratio shall be determined taking into account only to the cylindrical shell
and the elliptical end as they are the only main pressure-bearing parts. Since these two parts are made of the
f
same material, they have the same ratio a .
f Td
   
 R p0,2 Rm  285 460 
fa = MIN  ;  = MIN  ; = 190 MPa
 1,5 2,4   1,5 2,4 
   
Then and fTd = 184 MPa (see Table 4.1-1 of this report for the
mechanical properties at room temperature):
With these values, the test pressure shall be the greater of:
fa
Pt = 1,25 Pd (10.2.3.3.1-1)
fTd
190
Pt = 1,25 × 44 × = 56,79 bar (10.2.3.3.1-1)
184
and
Pt = 1,43 Ps (10.2.3.3.1-2)
Pt = 1,43 × 44 = 62,92 bar (10.2.3.3.1-2)
Therefore the value of the test pressure is:
Pt = 62,92 bar.
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7.6.4 Acceptance criteria
10.2.3.9 of EN 13445-5:2009 reproduced below gives the acceptance criteria:
7.7 Marking and declaration of compliance with the standard
Clause 11 of EN 13445-5:2009 gives the requirements to be fulfilled for the marking of the pressure vessel.
Two methods are proposed:
— Direct stamping on the pressure vessel,
— Separate nameplate.
The nameplate is selected and requirements of 11.2.2 shall be applied.
The content is described, as a minimum, in 11.4.
After that, declaration of compliance to EN 13445 shall be conducted in accordance with Annex H (Informative) of
EN 13445-5:2009.
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Unfired pressure vessels

TECHNICAL REPORT CEN/TR 13445-101

Unfired pressure vessels - Example of application

EUROPEAN COMMITTEE FOR STANDARDIZATION

CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels

— Design and calculation;

— Inspection and testing;

using the following part of EN 13445:

EN 287-1:2004+A2:2006, Approval testing of welders — Fusion welding — Part 1: Steels

EN 764-5:2002, Pressure Equipment — Part 5: Compliance and Inspection Documentation of Materials

EN 10204:2004, Metallic products — Types of inspection documents.

The target vessel consists of several components:

— two elliptical ends,

— a welding neck flange,

— two saddle supports arranged symmetrically

3.2 Pressure vessel data

Figure 1 — Pressure vessel data

Normal service conditions:

— Internal pressure: 44 bar

— Minimum metal temperature: -20 °C

— Liquid group 1, density: 0,54

— Pressure loading predominantly of non-cyclic nature

There are not exceptional service conditions.

PED 97/23/CE regulation applies.

3.3 PED 97/23/CE Category

3.4 Extracts from EN 13445-1 to EN 13445-5:2009 and from others standards

4.2 Minimum requirements for materials

The following clauses of EN 13445-2:2009 shall be fulfilled:

4.2.2 Minimum elongation

Figure 2 — Abstract from EN 13445-2:2009

4.2.3 Impact test for ferritic steel

Figure 3 — Abstract from EN 13445-2:2009

4.2.4 Chemical composition of selected grade

— %C: 0,38 to 0,45;

Figure 4 — Abstract from EN 13445-2:2009

4.3 Mechanical properties of the chosen materials

Figure 5 — Abstract from EN 13445-2:2009

Cylindrical EN 10028- P295GH 27 J @

EN 10216- P275NL2 EN 13445- 47 J @

Reinforcing EN 10028- P295GH 27 J @

4.4 Type of material certificate

4.4.1 PED requirements

4.4.2 Type of certificate for pressure vessel components

Figure 6 — Abstract from EN 764-5:2002

Figure 1 of EN 764-5:2002 below is useful to determine the type of certificate:

Figure 7 — Abstract from EN 764-5:2002

4.5 Prevention of brittle fracture

4.5.2 Method 1 (B.2.2 of EN 13445-2:2009)

4.5.2.2 Determination of test temperature TKV

— Plates and strip

Figure 8 — Abstract from EN 13445-2:2009

Figure 9 — Abstract from EN 13445-2:2009

Figure 10 — Abstract from EN 13445-2:2009

— Nuts and bolts

Figure 11 — Abstract from EN 13445-2:2009

4.5.3 Method 2 (Clause B.2.3 of EN 13445-2:2009)

The following definitions are given by EN 13445-2:2009 and apply:

Figure 12 — Abstract from EN 13445-2:2009

4.5.3.3 Impact energy requirements

Figure 13 — Abstract from EN 13445-2:2009

4.5.3.4 Determination of the test temperature TKV