2013

FEA of Pressure Vessel

and Nozzle Junction

DHARMIT THAKORE

MOONISH ENTERPRISES PTY LTD |

Executive Summary
The main objective of this project was to understand the Finite Element Analysis capability of Open
Source Software Salome for Pre-processing and Post-processing and Code_Aster for analysis of a
Pressure Vessel Nozzle junction. To obtain hexahedral mesh for the Pressure Vessel Half geometry.
To analyse and compare Deflection and Vonmises stresses for three load cases for the geometry,
Internal Pressure only, Force on Nozzle Only and a combination of Internal Pressure and Force on
Nozzle. The main goal was to calculate Stresses by hand and compare them with the Finite Element
Analysis results.
Analysis was carried out on a half section of a pressure vessel with nozzle in the middle of the
geometry, with sufficient symmetry and boundary conditions added for stability of the model.
Linear analysis using hexahedral elements was carried out for this study.
Salome version 6.3.0 and Aster version 1.10.0 was used for this analysis.
From the study it can be seen that hand calculations closely match the Finite Element Analysis
results for the geometry away from the Pressure Vessel and Nozzle junction. An effort has been
made to calculate Membrane and Bending Stresses for comparison only at two Stress Classification
lines at the Nozzle Pressure Vessel Junction. Further studies are required to evaluate stresses and
analyse them based on ASME Section VIII Division 2 Part 5 rules and to obtain Membrane, Bending
and Peak stresses.

Table of Contents
Executive Summary................................................................................................................................. 1
Introduction ............................................................................................................................................ 3
Model Geometry ..................................................................................................................................... 4
Mesh ..................................................................................................................................................... 17
Loads and Restraints ............................................................................................................................. 22
Analysis of results ................................................................................................................................. 26
Internal Pressure only ....................................................................................................................... 26
Force Only ......................................................................................................................................... 29
Pressure and Force applied together................................................................................................ 32
Conclusions ........................................................................................................................................... 37

Introduction
The main goal of this study was
1. To Model Pressure Vessel with Nozzle Geometry (Show step by step method of how is it
done in Salome)
2. Partition it to make it ready for Hexahedral meshing
3. Mesh it with Hexahedral elements
4. Perform Finite Element Analysis with 3 load cases
a. Internal pressure (both Hoop and Longitudinal stresses)
b. Force of 9000N on Nozzle in Lateral direction to vessel geometry
c. Combination of both a and b
5. Study the Stresses developed around the Nozzle Geometry (Discontinuity)
6. Compare the results with Hand Calculations
Salome was used to model the geometry. The geometry modelling is carried out in Salome
Geometry module, meshing was carried out in Salome Mesh module and then the mesh was
exported in .msh format. Finite Element Analysis was carried out in Code_Aster and the results were
exported in .msh format. This result mesh was imported in Salome again and Post Processing was
carried out where Displacements and Vonmises stresses were evaluated.
In this study Static Linear Finite Element Analysis was used to obtain results. Hexahedral mesh was
used for this study. Quadratic mesh was not considered for this study.
Vonmises stresses were calculated for the 3 load cases above and they were compared with hand
calculations using first principles.
Membrane and Bending stresses were calculated for two Stress Classification Lines (SCL) for all three
load cases and are presented for comparison purposes only.

Model Geometry
The model geometry is a half section of a Pressure Vessel modelled in positive X-Z zone of the coordinate system. This pressure vessel has a nozzle at the centre of it pointing in positive X direction.

Half model of the entire pressure vessel was used in this study as the not-modelled section of the
pressure vessel was very remote to the Nozzle geometry. Flange was not modelled on the nozzle
end to minimise mesh size and computation time as this is the standard practice used in commercial
software packages.
Solid modelling was carried out in this study with following parameters.

OD of Pressure Vessel Shell = 3000mm

OD of Nozzle = 300mm
Height of the Pressure Vessel Shell = 3000mm

ID of Pressure Vessel Shell = 2980mm

ID of Nozzle = 280mm
Height of the Nozzle = 200mm

Modelling steps for the entire geometry are described below

Salome -> Geometry Module

New Entity -> Basic -> Point -> First

Argument (Point by 3 Co-ordinates)

Name: Reference1; X: 0; Y: 0; Z: 1500;

Click Apply and Close

New Entiry -> Basic -> Vector ->

Second Argument (Vector by 3 Coordinates)

Name: Vx; X: 10; Y: 0; Z: 0; Click

Apply

Name: Vy; X: 0; Y: 10; Z: 0; Click

Apply

Name: Vz; X: 0; Y: 0; Z: 10; Click

Apply and Close

New Entiry -> Primitive ->

Cylinder -> Second Argument
(Cylinder by Radius and Height)

Name: Cylinder_1; Radius:

1500; Height: 3000; Click
Apply

Name: Cylinder_2; Radius:

1490; Height: 3000; Click
Apply

Still in Cylinder Modelling Select

First Argument (Cylinder by
Base Point, Vector, Radius and
Height)

Name: Cyliner_3; Base Point:

Reference1; Vector: Vx; Radius:
150; Height: 1700; Click Apply

Name: Cyliner_4; Base Point:

Reference1; Vector: Vx; Radius:
140; Height: 1700; Click Apply
and Close

Operations -> Boolean ->

Fuse -> Default Argument

Name: Fuse_1; Object 1:

Cylinder_1; Object 2:
Cylinder_3; Click Apply

Name: Fuse_2; Object 1:

Cylinder_2; Object 2:
Cylinder_4; Click Apply
and Close

Operations -> Boolean ->

Cut -> Default Argument

Name: Cut_1; Main

Object: Fuse_1; Tool
Object: Fuse_2; Click
Apply and Close

Right Click Cut_1 in Object Browser and Select Show Only

New Entiry -> Primitive -> Box > Second Argument Box by
Dimensions at Origin)

Name: Box_1; Dx: 1500; Dy:

3000; Dz: 3000; Click Apply
and Close

Operations ->
Transformations ->
Translation -> First
Argument (By Dx, Dy, Dz)

Objects: Box_1; Dx: 1500; Dy: -1500; Dz:0;

Uncheck Create a Copy;
Click Apply and Close

Operations -> Boolean -> Cut -> Default Argument

Name: Cut_2; Main Object: Cut_1; Tool Object: Box_1; Click Apply and Close
Right Click Cut_2 in Object Browser and Select Show Only

New Entiry -> Basic -> Plane ->

First Argument (Plane by Point
and Vector)

Name: Plane_1; Point:

Reference1; Vector: Vy; Size of
Plane: 7000; Click Apply

Name: Plane_2; Point:

Reference1; Vector: Vz; Size of
Plane: 7000; Click Apply and
Close

Operations -> Partition -> First

Argument (By Objects and Tool
Objects)

Name: Partition_1; Objects:

Cut_2; Tool Objects: Plane_1 &
Plane_2; Click Apply and
Close

Right Click Partition_1 in Object Browser and Select Show Only

Point

Point

P1

P2

While Partition_1 is selected in Object Browser

New Entiry -> Group -> Create -> First Argument (Shape Type Points)
Group Name: P1; Main Shape: Partition_1; Select Point on the extreme Y @ Z = 1500 (as
shown in above figure); Click Add; Click Apply
Group Name: P2; Main Shape: Partition_1; Select Point on the extreme +Y @ Z = 1500 (as
shown in above figure); Click Add; Click Apply and Close

New Entity -> Basic -> Point -> First Argument (Point by 3 Co-ordinates)
Name: P3; X: 1500; Y: 0; Z: 2250; Click Apply
Name: P4; X: 1500; Y: 0; Z: 750; Click Apply and Close

New Entiry -> Basic -> Plane -> Second Argument (Plane by 3 Points)
Name: Plane_3; Point 1: P1; Point 2: P2; Point 3: P3; Size of Plane: 7000; Click Apply
Name: Plane_4; Point 1: P1; Point 2: P2; Point 3: P4; Size of Plane: 7000; Click Apply and
Close

Operations -> Partition -> First Argument (By Objects and Tool Objects)
Name: Partition_2; Objects: Partition_1; Tool Objects: Plane_3 & Plane_4; Click Apply and
Close
Right Click Partition_2 in Object Browser and Select Show Only
Right Click Partition_2 -> Transparency: 70%

Right Click Cylinder_1 in

Object Browser and Select
Show Only

New Entiry -> Group -> Create > Third Argument (Shape Type
Faces)

Group Name: PV_OD; Main

Shape: Cylinder_1; Select
Cylindrical Surface of
Cylinder_1; Click Add; Click
Apply and Close

Right Click Cylinder_3 in

Object Browser and Select
Show Only

New Entiry -> Group -> Create -> Third Argument (Shape Type Faces)

Group Name: Nozzle_OD; Main Shape: Cylinder_3; Select Cylindrical Surface of Cylinder_3; Click
Add; Click Apply and Close

Right Click Partition_2 in Object Browser and Select Show Only

Operations -> Partition -> First Argument (By Objects and Tool Objects)
Name: PV; Objects: Partition_2; Tool Objects: PV_OD & Nozzle_OD; Click Apply and Close

Right Click PV in Object Browser and Select Show Only

Face
Face
PrLong
DxDy

Face
Dx

Face
ForceE

Face
Dz
New Entiry -> Group -> Create -> Third Argument (Shape Type Faces)
Group Name: DxDy; Main Shape: PV; Select Right Vertical Face of the PV Shell if you are
standing at Origin looking at the Nozzle in +X direction; Click Add; Click Apply
Group Name: Dx; Main Shape: PV; Select Left Vertical Face of the PV Shell if you are standing
at Origin looking at the Nozzle in +X direction; Click Add; Click Apply

Group Name: Dz; Main Shape: PV; Select Bottom Horizontal Face of the PV Shell; Click Add;
Click Apply
Group Name: PrLong; Main Shape: PV; Select Top Horizontal Face of the PV; Click Add; Click
Apply
Group Name: IntPress; Main Shape: PV; Select All Inside surfaces of the Pressure Vessel Shell
and Nozzle (There should be 20 faces to be selected); Click Add; Click Apply
Group Name: ForceE; Main Shape: PV; Select Front face of the Nozzle; Click Add; Click Apply
and Close

Following step is only required if you want to have a Sub Mesh in the thickness of the Shell and
Nozzle.
Still in Group Create -> Select Second Argument (Shape Type Wire)
Group Name: Sub5; Main Shape: PV; Select all Edges in the Shell Thickness at the Vertical
and Horizontal Faces of the Shell, Select all Edges in the Nozzle Thickness (hdf file for
this study is available for download); Click Add; Click Apply

Right Click PV in Object Browser and Select Show Only

This concludes Modelling exercise for the Pressure Vessel.

Mesh
Entire geometry is meshed with 3D Linear Hexahedral elements.
Global geometry was meshed with 3D Algorithm of Hexahedron (I,j,k), 2D Algorithm of Quadrangle
(Mapping) and 1D Algorithm of Wire Discretisation with Hypothesis of Nb Segments of 50
Equidistant distribution.
Following steps assumes that you are in Mesh module of Salome
Mesh -> Create Mesh
Name: PV; Geometry: PV (Select PV geometry from Geometry Module); 3D Tab: Algorithm:
Hexahedron (i,j,k); 2D Tab: Algorithm: Quadrangle (Mapping); 1D Tab: Algorithm: Wire
discretisation: Hypothesis: (Click Add Hypothesis Button and select) Nb_Segment; In Hypothesis
Construction: Name: (Default) Nb. Segments_1; Number of Segments: 40; Type of distribution:
Equidistant distribution; Click Ok; Click Apply and Close

Shell thickness was given a Sub

Mesh with 1D Algorithm of Wire
discretisation, with Hypothesis of
Nb Segments of 5 Equidistant
distribution and Additional
Hypothesis of Propogation of 1D
Hypothesis on opposite edge.
Right Click PV in Mesh Module in
Object Browser and Select Create
Sub-mesh
Name: (Default)
SubMesh_1; Mesh: PV; Geometry:
(Select) Sub5 (from Geometry Module); 1D Tab: Algorithm: Wire discretisation: Hypothesis: (Click
Add Hypothesis Button and select) Nb_Segment; In Hypothesis Construction: Name: (Default) Nb.
Segments_2; Number of Segments: 5; Type of distribution: Equidistant distribution; Click Ok; Add.
Hypothesis: (Click Add Hypothesis Button and select) Propagation of 1D Hyp. On opposite edges;
Click Apply and Close

Right Click PV in Object Browser and Select Compute

Close-up of the Nozzle Mesh.

This mesh is suitable for Studying

stresses generated in Pressure
Vessel Shell. It is good for evaluating
Bending, Peak and Membrane
stresses in and around the Shell
Nozzle junction. Better Stress
distribution can be obtained by
using Quadratic meshing which will
be done in future studies.

Right Click PV in Object Browser

and Select Create Groups from
Geometry

Mesh:PV; Geometry: (Select DxDy

from Geometry Module) DxDy; Click
Apply

Mesh:PV; Geometry: (Select Dx from

Geometry Module) Dx; Click Apply

Mesh:PV; Geometry: (Select Dz from Geometry Module) Dz; Click Apply

Mesh:PV; Geometry: (Select PrLong from Geometry Module) PrLong; Click Apply

Mesh:PV; Geometry: (Select IntPress from Geometry Module) IntPress; Click Apply

Mesh:PV; Geometry: (Select ForceE from Geometry Module) ForceE; Click Apply and Close

Right Click PV in Object Browser and Select Export to MED file

Select a location for the med file and save it.

Loads and Restraints

To provide Symmetric Boundary Condition to the Pressure Vessel following Boundary Conditions
were used.
1. Face DxDy was given Boundary condition of DX = 0.0 and DY = 0.0
2. Face Dx was given Boundary condition of DX = 0.0
3. Face Dz was given Boundary condition of DZ = 0.0

Three load cases were considered in this analysis

1. Internal Pressure of 0.5MPa applied on the Internal Face of the pressure vessel
2. Force of Fy = 9000N applied on the face of the flange
3. Combined Internal Pressure and Force

To account for the discontinuity in the Pressure Vessel shell, force equivalent to the Pressure acting
on the inside of the Nozzle was applied in Fx direction on face ForceE. If this balancing force was
not applied, Pressure Vessel Ovalization occurred due to un-balanced distribution of the Pressure on
internal face.

.comm file used for analysis with Code_Aster is shown here for easy reference. This file is
commented sufficiently to give information on what is going on.

DEBUT();

#Define Material Steel

Steel=DEFI_MATERIAU(ELAS=_F(E=210000.0,
NU=0.3,),);

#Read the mesh in 'MED' format

MAIL=LIRE_MAILLAGE(FORMAT='MED',);

#Assign the model Mechanical and in 3D

MODE=AFFE_MODELE(MAILLAGE=MAIL,
AFFE=_F(TOUT='OUI',

PHENOMENE='MECANIQUE',
MODELISATION='3D',),);

#Assign the material Steel previously defined

MATE=AFFE_MATERIAU(MAILLAGE=MAIL,
AFFE=_F(TOUT='OUI',
MATER=Steel,),);

#Boundary Condition 'Base' is Fixed in all directions

BCs=AFFE_CHAR_MECA(MODELE=MODE,
FACE_IMPO=(_F(GROUP_MA='Dx',
DX=0.0,),
_F(GROUP_MA='DxDy',
DX=0.0,
DY=0.0,),
_F(GROUP_MA='Dz',
DZ=0.0,),),);

#To Balance Internal Pressure at Nozzle Junction

Press1 = 0.5;
NozOR = 150.0;
NozIR = 140.0;
NozArIR = 3.14 * NozIR * NozIR;
ForceBal = NozArIR * Press1;
ForceBal = ForceBal / (3.14 * (NozOR * NozOR - NozIR * NozIR));

#To apply Longitudinal Stress

PVOR = 1500.0;
PVIR = 1490.0;
PVArIR = 3.14 * PVIR * PVIR;

LongStr = PVArIR * Press1;

#Pressure is applied on 1/2 Area for Hoop and is resisted by 1/2 Area so 1/2 cancels out
LongStr = LongStr / (3.14 * (PVOR * PVOR - PVIR * PVIR));

#Force of 9000N is distributed over the Area of Nozzle Tip

ForceY = 9000. / (3.14 * (NozOR * NozOR - NozIR * NozIR));

Loads=AFFE_CHAR_MECA(MODELE=MODE,
PRES_REP=_F(GROUP_MA=('IntPress'),
PRES=Press1,),
FORCE_FACE=(_F(GROUP_MA='PrLong',
FZ=LongStr,),
_F(GROUP_MA='ForceE',
FY=ForceY,),
_F(GROUP_MA='ForceE',
FX=ForceBal,),),);

RESU=MECA_STATIQUE(MODELE=MODE,
CHAM_MATER=MATE,
EXCIT=(_F(CHARGE=BCs,),
_F(CHARGE=Loads,),),);

#Calculate fields on Elements

RESU=CALC_ELEM(reuse =RESU,
RESULTAT=RESU,
OPTION=('SIEF_ELNO','SIEQ_ELNO','SIGM_ELNO'),);
#Calculate fields on Nodes
RESU=CALC_NO(reuse =RESU,
RESULTAT=RESU,
OPTION=('SIGM_NOEU','SIEQ_NOEU','REAC_NODA',),);

#Dump the entire result in a text file

IMPR_RESU(FORMAT='RESULTAT',
RESU=_F(MAILLAGE=MAIL,
RESULTAT=RESU,
NOM_CHAM=('SIEQ_ELNO','SIEQ_NOEU','DEPL','REAC_NODA','SIGM_NOEU'),),);

#Dump the result in .med file that can be read by Salome

IMPR_RESU(FORMAT='MED',
UNITE=80,
RESU=_F(MAILLAGE=MAIL,
RESULTAT=RESU,
NOM_CHAM=('SIEQ_ELNO','SIEQ_NOEU','DEPL','REAC_NODA','SIGM_NOEU'),),);

FIN();

The output from the analysis is saved as a .med file that can be read by Salome and used for Post
processing.

Analysis of results
-

Present the displacement and Stress results (Including plots and animation)

Internal Pressure only

The first of the three cases analysed was Internal Pressure only
Internal Pressure of 0.5MPa is applied to the inside of the Pressure Vessel and Nozzle. The
displacement and VonMises stresses are shown below
Below is the snapshot of displacement with scale factor of 100. Maximum displacement is 1.2mm.
This is inline with the growth of diameter of the vessel as calculated manually.

Below is the displacement upclose near the nozzle.

The Vonmises stress snapshot is shown below

Below is the Vonmises stresses upclose

Vonmises stresses on the inside of the Pressure Vessel

Vonmises stresses on the inside upclose

Vonmises stresses remote to the nozzle is 65MPa which is inline with the hand calculation.

Force Only
Force of 9000N is applied on the face of the Nozzle in Fy direction.
The displacement and Vonmises stresses for Force Only case is shown below.

Displacement upclose

Vonmises stresses for the Force only is shown below

Vonmises stresses upclose

Vonmises on the inside of the Pressure Vessel

Vonmises on the inside upclose

Pressure and Force applied together

The combination of Pressure and Force will see some stresses around the nozzle increase but the
overall stresses in the pressure vessel remote to the nozzle should remain unchanged and that is
what is seen in the analysis.
Displacement for Pressure and Force.

Displacement upclose

Vonmises stresses

Vonmises upclose

Vonmises on the inside of the pressure vessel

Vonmises stresses on the inside of the pressure vessel upclose

As can be seen above in the Vonmises stresses on the inside of the Pressure Vessel, the equivalent
stresses have fallen from 231 MPa in Pressure Only case to 198 MPa in Pressure and Force case.
For evaluation and comparison purposes, Bottom Negative Y Quarter section of the nozzle is shown
with VonMises Stresses for all three load cases. First Column is for Pressure Only Load case, Second
Column is for Force Only Load Case and Third Column is for combined case. First Row is showing
complete Clipped Model, Second Row is showing SCL2 and Third row is showing SCL1.
Pressure Only

Force Only

Pressure and Force

Two stress Classification Lines were taken for this study and the tabulated SIXX, SIYY, SIZZ, SIXY, SIYZ,
SIZX, Vonmises total along with Membrane and Bending stresses are presented here

SIXX
SIYY
SIZZ
SIXY
SIYZ
SIZX
Total

SIXX
SIYY
SIZZ
SIXY
SIYZ
SIZX
Total

Pressure Only
SCL1
Membrane
Bending
Stress (MPa)
Stress (MPa)
1.788
23.151
144.799
25.550
15.043
32.353
-0.749
8.916
0.820
4.348
-0.027
-0.012
136.878
19.068
SCL2
Membrane
Bending
Stress (MPa)
Stress (MPa)
-0.5452
20.4399
40.758
16.022
-27.977
36.552
-7.528
1.658
0.676
9.302
-0.075
-0.018
61.342
24.862

Force Only
SCL1
Membrane
Bending
Stress (MPa)
Stress (MPa)
0.785
9.095
-0.978
13.669
-0.927
11.156
-3.143
4.090
-0.010
-0.003
-0.041
0.001
5.715
8.119
SCL2
Membrane
Bending
Stress (MPa)
Stress (MPa)
-0.192
-0.816
0.225
-1.435
0.026
-1.651
-0.771
0.016
0.087
-0.407
-2.992
4.272
5.365
7.470

Pressure and Force Only

SCL1
Membrane
Bending
Stress (MPa)
Stress (MPa)
-0.477
38.419
8.365
60.677
32.305
44.083
-11.720
17.051
-0.022
-0.007
-0.093
0.004
35.708
35.689
SCL2
Membrane
Bending
Stress (MPa)
Stress (MPa)
3.052
23.185
161.190
8.121
26.079
41.271
-0.773
0.011
1.197
14.879
-3.014
4.256
148.087
39.305

Evaluation of the stresses is left to the reader.

Future aspirations from this analysis are to perform FEA based on ASME Section VIII Division 2 Part 5
rules. Use Stress Classification line to find out Membrane, Bending and Peak stresses which shall be
carried out in future analysis and documented in a report.
Vonmises stresses were used as a criteria to determine equivalent stress for comparison.

Conclusions
From this study it can be concluded that Finite Element analysis results match that of hand
calculations at location remote to the Nozzle Pressure Vessel junction. This study is not exhaustive
and was conducted to try modelling Pressure Vessel geometry and partition it to make it ready for
meshing, To mesh the Pressure Vessel geometry with Hexahedral mesh, To carry out Finite Element
analysis of a Pressure Vessel Nozzle section using Code_Aster for analysis, And to perform Post
Processing using Salome.
Outcome of the analysis can be summarised as
1. Salome can be used as a competent software to model the geometry, Mesh it and perform
Post Processing on the results
2. Code_Aster is a powerful software but due to it being in Non-english format is a restriction.
3. Open Source softwares can be used for performing FEA based on ASME Section VIII Division
2 Part 5.

This study is just a preliminary analysis. For further study following actions are recommended
1. Use of 2nd order or Higher order elements
2. Mesh refinement around the nozzle shell junction
3. Evaluate Stresses based on ASME Section VIII Division 2 Part 5 rules.