Foreword
In August of 1965 the Welding Research Council published WRC Bulletin No. 107, "Local Stresses in Spherical and
Cylindrical Shells Due to External Loadings," by K. R. Wichman, A. G. Hopper and J. L. Mershon. That document provided
engineers with guidance for the evaluation oflocalized stresses in pressure vessel shells due to various extemalloads.
Less than 20 years later, in August of 1984, the Welding Research Council published Bulletin No. 297, "Local Stresses in
Cylindrical Shells Due to External Loadings on Nozzles-Supplement to WRC Bulletin No. 107," by J. L. Mershon, K.
Mokhtarian, G. V. Ranjan and E. C. Rodabaugh. This document provided important improvements to WRC Bulletin No. 107,
accounting for local stresses in the nozzle, as well as, the vessel. The basis for the curves in Bulletin No. 297 was the computer
code developed by Dr. C. R. Steele entitled, FAST2.
The work presented here provides the engineer with guidance for the evaluation of shell and nozzle stresses due to internal
pressure. Eqs. 1 through 4 are based on parametric studies performed with the computer code FAST2. The bulletin also
includes comparisons with other previously developed correlation equations and test data.
It is important that it be recognized that this bulletin does not present any rules for design, but it is rather intended to be an
aid in assessing the local structural integrity of the vessel. No attempt is made to educate or enlighten the individual on stress
categorization rules of Section III or Section VIII, Division 2 of the ASME Boiler and Pressure Vessel Code. It is taken for
granted that the designer understands how, when and where to apply the categorization rules for calculating stresses in
accordance with the methods in this document.
G. E. o. Widera, PhD
Chairman of Committee on Reinforced
Openings and External Loadings of
the Pressure Vessel
Research Council
Stresses in Intersecting Cylinders Subjected to Pressure
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Stresses in Intersecting Cylinders Subjected to Pressure 7
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The foll owing are the four proposed equations for the width of shell reinforcement (pad plate or insert
design: plate) is less than 1.65 ,mT or d 12, then the " T "
Maximum membrane stress intensity on vessel: value to be used for calculating stresses is to be the
th ickness of the shell . (This ignoring of the s hell
fJ, ~ [0 .5315 - 0.06342 (D Id) '" (D / T) - '" reinforcement may result in overly conservative esti-
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estimate of stresses in the nozzle neck.) If the width
. [(d l /Dt) x (PD I2T)) (1) of the shell reinforcement (pad plate 01' insert plate) is
equal to or greater than 1.65 ,mT and d 12, it can be
Maximum surface stress intensity on vessel assumed that the thickness of the reinforced portion
IT" ~ [1.0048 - 0.01427 (t 1T) - '5 of the shell would determine the state of stress at the
nozzle-to-shelljunction. In such a case, the "Tn value
+ 0.8605 (D Id)'" (D I T)-0 5 (tiT)" ] to be used in equations for calculating stresses shall
. [(d l/Dt) x (PDI2T)] (2)
be "T," (the t hickness of insert plate or shell thick-
ness plus pad plate thickness). It is generally assumed
Maximum membrane stress intensity on nozzle t hat discontinuity stresses due to t he penetration
have been reduced to negligible levels at a distance of
fJ" ~ [0.2728 - .04706 (D ld )o," (t 1T) -050 + 0.9551
1.65 ,mT or d 12, whichever is greater, from the
. (D IT to.25 (t IT )O'''') [(D I .j(Fh x (Pd / 2t)) (3) nozzle neck.
Maximum surface stress intensity on nozzle
6,0 Comparison with Other Equations
u" ~ [0.3377 - 0.5272 (D l d) -'" (t IT) - "
To show how the equations proposed in this Bulle-
+ 1.4229 (D ld t" (t IT) - " ][(D /JdT) x (Pd I2t») (4 ) tin compare with four other equations proposed in
other papers, plots are provided to indicate the maxi-
mum surface stress difference between each equation
5.0 Limitations
a nd FAST2 resu lts. For these comparisons, all 99
It is suggested that the use of design formu las data po in ts h ave been used, even though some of t he
proposed in this Bulletin be limited to the follow ing data fall outside of the range of geometric parameters
range of parameters: specified for these other equations. The four other
equations are from Ref. 2 and are shown below. (For
10 < D IT < 1000 the source of t hese equations and their range of
4 < d lt < 1000 applicability, see Ref. 2.)
0.1 < t i T < 3 SCF ~ 2.8(D /T)°"" (dl D)°367 (t/ T) -o.", (I',/t) -" " (5)
0.03 < dID < 0.5 SCF = 2.1 [A I(t IT)) H' (6 )
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difference between Eq. 5 and F AST2 are for D IT > . 26 thru 31 merely indicate the degree of accuracy that
100, which is outside the range that is specified for can be expected, when arriving at maximum stresses
useofEq.5. at cylinder intersections by various means.
Since the four equations proposed by others and
shown here provide only maximum stress values, 8.0 Examples
their percent difference results (Figs. 2a-2d) should
be compared to Fig. 1f. Such comparison indicates The following examples have been included to
that the equations proposed here (Eqs. 1-4) have demonstrate the application of proposed equations.
much better correlation with FAST2 results than do They also provide a comparison of results obtained by
the equations developed by others. These proposed this method with the results obtained from a number
equations also cover a wider range of parameters than of other methods. Some suggestions are included on
allowables and how these results may be used for
the others.
Tables 2a and 2b list the values of % difference various Code calculations.
It should be pointed out that, for all the following
between SCF from Eqs. 1 thru 4 and FAST2 values.
Also listed are comparisons between the maximum examples, it has been assumed that the internal
membrane SCF (Eq. 1/3) and maximum surface SCF pressure is the only load applied to the intersections.
(Eq. 2/4) at the junction and FAST2 results. Please If piping loads or other mechanical loads are specified,
note that the maximum SCF at the junction is their effect will have to be included. Since no location
obtained by normalizing the maximum stress with or orientation is assigned to the stresses calculated by
PDI2T, regardless of location. (Values for Eqs. 3 and
these proposed equations, it will not be possible to
4 have been normalized with Pd/2t). Tables 2c and 2d accurately calculate the value of stress intensity due
list the values of % difference between SCF of Eqs. 5 to combined loads. It is possible, however, to calculate
thru 8 and FAST2 results. For reference, the % an upper bound on combined stresses by adding the
difference column for Eq. 2/4 has been repeated here. maximum stresses calculated due to internal pres-
sure to corresponding maximum stresses calculated
7.0 Comparison with Test Results and Finite due to other loadings. WRC Bulletin 297 6 provides
Element Results means of calculating membrane and surface stresses
in vessel and nozzle, due to piping loads. The absolute
Ref. 4 tabulates the available finite element analy- value of those stresses will have to be conservatively
sis results and test results for cylinder intersections. added to the corresponding stresses calculated for
To avoid duplication, the details of the references to pressure. Also, if thermal stresses are present, they
these results are not included here. The reader is will have to be included for those cases which require
referred to Ref. 4 for discussion of these available a limit on secondary stresses.
results. On pages 26 thru 31 the tables 1A thru 1C,
2A, 2B, 3 thru 8, and 27 of Ref. 4 have been duplicated E~ple No. l-Unreinforced Opening
with the values of stress concentration factor ob- GIven:
tained from the equations proposed in this ~aper D = 120 in. T = 0.5 in. d = 48 in. t = 0.5 in.
added. The column marked "SCF" is the value of
P = 120 psi MaterialA-516-70 joint efficiency = 1.0
stress concentration factor reported by the reference
for analysis or test results. The values in the column corrosion allowance = 0
"Eq. (2/4)" are the calculated maximum stress val- Parameters of Interest:
ues divided by PD/2T. The values for Eqs. 5 thru 8
have all been normalized by PDI2T. DIT = 240 d/t = 96 = 2.5
D/d dlJDT = 6.2
The tables provide an indication of how the maxi- Sis = 14400/5760 = 2.5 tIT =1
mum stress concentration factors for Eqs. 1-4 pro-
posed here and from Eqs. 5 thru 8 compare with the All the parameters fall within the limits of applicabil-
reported finite element or test results. The average ity of equations proposed here. Calculation of maxi-
ratio and standard deviations are provided as a mum stresses by use of the Eqs. 1 thru 4:
measure of data fit. It should be noted that the Membrane stress in vessel
geometric parameters for many of the models fall
O'u = [0.5315 - 0.06342 (2.5)1.25 (240t· 25(1)-O.75
outside of the range of applicability of the equations
~roposed here. However, all models have been kept to + 0.4372(2.5)(240)-·25(1)-·25][(48/ J120 x .5)
IndIcate the accuracy or inaccuracy of equations
proposed here over a wide range of parameters. The x 14,400] = 4.70 x 14,400 = 67,700 psi
accuracy of finite element results or test results Surface stress in vessel
cannot be easily ascertained. Stress gradients on
O'll = [1.0048 - .01427(1t 1.5
nozzle corners are quite steep and strain gages would
have to be located very accurately to pick up maxi- + 0.8605(2.5)1.25 (240)-·5(1}5]
mum value of stresses. Similarly, the finite element
mesh would have to be extremely fine to provide . [(48/ J120 x .5) x (14,400)]
accurate results. Comparisons of the Tables on pages = 7.22 x 14,400 = 104,000 psi
Model Lambda Eq. (1) Eq. (2) Eq.(3) Eq. (4 ) Eq. (1/3) Eq. (2/4)
Model Lambda Eq.(2/4) Eq. (5) Eq. (6) Eq. (7) Eq. (8)
lng membrane stresses due to pressure area. For 12.8 in. and dl2 = 24 in. Section VIII, Division 1,
calculating bending stresses, it assumes an effective allows a pad as wide as 24 in. to be considered
section extending 16T along vessel shell and 16t along effective for reinforcement [Paragraph UG-40 (a)
(1)]. The use of a 24 in. wide pad provides a total
the nozzle, to resist combination of in-plane and
reinforcement area of approximately 28.5 square in.,
out-of plane moments.
~hich is more.than the required area of 19.8 square
Membrane and membrane plus bending stresses, in
In. However, SInce the size of the opening exceeds the
the vessel, calculated by this method are 48,140 and
l~its of Paragraph UG-36 (b) (1), the compact
73,900 psi, respectively. These values are consider-
reInforcement rules of Appendix 1-7 will also have to
ably smaller than the stresses calculated by equations
be met. This requires that % of the reinforcement
~ro~osed here (67,700 psi and 104,000 psi). But, the
area be placed within an approximately 12 in. width
~lImts of effective sections in Ref. 5 are arbitrary and
of the pad. For this case, there is approximately 14.42
mtended for approximation of stresses over a wide
square in. of reinforcing material within the compact
range of parameters. The method of Ref. 5 is also reinforcing limits, which is more than the required
intended to provide an estimate of average primary
area of 13.21 square in. A 24 in. wide and 0.5 in. thick
membrane and primary bending stresses, and pro-
pad, therefore, meets the requirements of Section
posed allowables are those associated with primary VIII, Division 1, Code.
stresses. Whereas the stresses based on F AST2 pro- With such pad, the parameters, used for calculating
~am i~cl':lde the local membrane and secondary
stresses by use of equations proposed here, are:
discontInulty effects. These results can be classified
as local primary membrane and secondary bending D = 120 in. T = 1.0 in. d = 48 in.
stresses. t = 0.5 in P = 120 psi
An approach similar to that of Ref. 5 has been
successfully used by Chicago Bridge & Iron Company DIT = 120 dlt = 96 DId = 2.5 dlJiiT = 4.38
for design of large penetrations, over the past 25 SIs = 7,200/5,760 = 1.25 tIT = 0.5
Stresses in Intersecting Cylinders Subjected to Pressure 21
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