TomBarsh (Structural) 7 Mar 07

10:54
I have been asked a number of times "how do I determine the maximum loads that
can be applied to a nozzle?" Even in my work pre-Codeware this question often came
up.

It's a reasonable question, the vessel owner simply wants to know what maximum
load they can apply to their new vessel. But there is no simple answer. This is
because there is really an infinite number of combinations of loads that all produce
the same stress in the shell. By definition, this stress equals the allowable stress.

Below is part of an FAQ to be posted to the Codeware website that addresses this
issue.

Many engineering companies or vessel owners publish vessel design standards with
specified loads that the vessel nozzles are to be designed for. But in some cases the
vessel designer is asked to determine the maximum loads that the nozzle and vessel
may withstand. For this there is no published standard by ASME, etc. Each problem
must be approached separately because the answer will depend on the specific
properties of the vessel and nozzle; ie: the answer will depend on the pressure,
temperature, allowable stress, and the diameter and thickness of the shell and the
nozzle. In fact, due to the nature of the engineering problem (the existence of
combination of 3 forces and 3 moments to derive a single stress intensity) there is an
infinite set of loads that will all produce the maximum stress in the shell as per the
WRC-107 analysis.

Several issues relate to designing nozzles for the external loads: The nozzles must be
designed so that the nozzle neck itself is adequate for the bending moments and
axial and shear loads, as well as the welding being adequate. Generally the issues
most relevant are the magnitudes of the stresses in the shell resulting from the
external loads on nozzles. These stresses are often calculated using Welding
Research Council bulletin 107. The calculated stresses must be within the
corresponding allowable stresses. If nothing else governs, then by definition the
maximum external load will be that which produces a calculated stress equal to the
allowable stress.

The problem is that because the stresses in the shell result from a combination of 3
moments and 3 forces (2 bending moments, one torsional moment, one radial force,
and two shearing forces) there is an infinite number of combinations of forces and
moments that can all produce a calculated stress equal to the allowable stress. Thus
there is an unlimited number of combinations of external loads that may be the
"maximum external load" on the vessel; there is no single "magic combination".

The designer can manually determine a combination of loads and moments, or

several combinations, that produce maximum stress. A problem can arise if the
combination(s) provided to the customer are not satisfactory for their use and the
customer comes back and wants a different analysis. The designer can sometimes be
forced into an unproductive cycle of rework. Which may be okay if they are paid for
the work...but this generally is not the case.

In general, the shear forces VL and Vc and the torsional moment Mt do not contribute
to membrane stress; they contribute only to the shear stress which has only small
effect on the resultant stress. Thus the major contributors to the total stress are the
radial load P and the bending moment ML and Mc.

A procedure might be to determine a combination of forces and moments such that

the shear forces are equal to each other and equal to some fractional multiple of the
radial load (say, 10%), and assume that the bending moments are equal to the shear
forces multiplied by some eccentricity (say, 10"). And assume that the torsional
moment was same value. Thus the 3 moments and the 2 shears can be related to
multiples of the single unknown variable, which is the radial force. Of course, these
multiples are simply guesses and are up to the discretion of the designer.

COMPRESS provides an option that may help. The WRC-107 dialog contains several
options to "solve" for the maximum value of one of the following: +Pr (radial load),
-Pr, Mc, or ML. Note that because of the reversal of the load direction the radial load P
may have different maximum values depending upon its direction. The maximum
value found by COMPRESS is based on the simultaneous application of the values
specified for the remaining forces and moments plus the design internal pressure
(plus static head, if any). "Click" any of the four "Solve" option buttons and the
corresponding input field on the WRC-107 dialog will immediately change to the
maximum value for that load or moment. Another helpful tool is the fields at the
bottom of the dialog that immediately show the calculated primary membrane
stresses and the combined stress. Careful observation of the calculated stresses
while varying the input loads and moments can allow the designer to home in on a
reasonable set of "maximum loads" for the nozzle.

Tom Barsh
Codeware Technical Support