Proceedings of the ASME 2014 Pressure Vessels & Piping Conference

PVP2014
July 20-24, 2014, Anaheim, California, USA

PVP2014-28729

LARGE OPENINGS IN CYLINDRICAL PRESSURE VESSELS –

AN ASSESSMENT BASED ON ABSOLUTE SIZE

Dr. Dipak K. Chandiramani

Lloyd's Register Asia
63-64, Kalpataru Square, Kondivita Lane,
Chakala, Andheri, Maharashtra, Mumbai – 400059, India
Email: dipak.chandiramani@lr.org
Phone: +91-22-43250250

Shyam Gopalakrishnan Ameya Mathkar

Lloyd's Register Asia Lloyd's Register Asia
63-64, Kalpataru Square, Kondivita Lane, 63-64, Kalpataru Square, Kondivita Lane,
Chakala, Andheri, Maharashtra, Mumbai – 400059, India Chakala, Andheri, Maharashtra, Mumbai – 400059, India
Email: shyam.gopalakrishnan@lr.org Email: ameya.mathkar@lr.org
Phone: +91-22-43250250 Phone: +91-22-43250250

ABSTRACT This has been done by carrying out calculations for a wide
range of nozzle-shell combinations and comparing the results
Clauses UG-36 through UG-43 of ASME Section VIII so obtained with the results of a Finite Element Analysis.
Division 1 [1], describe the method of calculating the
adequacy of compensation of openings in shells, using an NOMENCLATURE
area-replacement method. The method is based on determining
and suitably replacing the missing metal area along any D Inside diameter of the shell course under
section, with metal available or provided, within the limits of consideration
reinforcement on the shell and nozzle. Dn Inside diameter of the nozzle under consideration
FEA Finite Element Analysis
Clause UG-36 (b) of ASME Section VIII Division 1 provides MAWP Maximum allowable working pressure
limits on the size of the opening for applicability of Clauses NPS Nominal Pipe Size
UG-36 through UG-43. If these limits are exceeded, P Maximum allowable pressure for the selected shell
supplemental rules of Clause 1-7 of Appendix 1 need to be geometry
complied with or alternatively the rules of Clause 1-10 of P1 Internal pressure at which the requirements of
Appendix 1 may be applied.
UG-37 are met for the particular nozzle-shell
configuration
The rules for large openings as stated in the Code are not
P2 P2a when only Clause 1-7(a) is applicable and
dependent upon the absolute size of the nozzle and shell. For
example, same calculations would be required to be carried lesser of P2a or P2b when Clause 1-7(b) is also
out whether a nozzle of NPS 1 is attached to a shell of NPS applicable
1.5 or a nozzle of NPS 16 is attached to a shell of NPS 24. P2a Internal pressure at which the requirements of
Clause 1-7(a) are met for the particular nozzle-shell
The work presented in this paper is an attempt to determine configuration
whether the additional calculations in Clause 1-7 need to be P2b Internal pressure at which the requirements of
carried out for finished openings exceeding the limits of UG- Clause 1-7(b) are met for the particular nozzle-shell
36(b) irrespective of the absolute size of the nozzle and shell. configuration

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 R Inside radius of the shell course under consideration STATEMENT OF THE PROBLEM
equal to D/2
Rn Inside radius of the nozzle under consideration It is often observed that vessel nozzle connections which are
equal to Dn/2 of small size have additional nozzles attached to them, as
SCL Stress Classification Line shown in Figure 1. Calculations for determining the adequacy
of compensation of an opening due to the additional nozzle in
the main nozzle need to be carried out and the rules of UG-37
INTRODUCTION are applied and the rules of Clause 1-7 are often invoked
requiring additional calculations.
Pressure vessel and piping Codes have used the area
replacement concept for at least 70 years. This concept,
described in Clause UG-37 of the Code [1] requires that the
metal cut out by an opening be replaced by reinforcement
within a prescribed zone around the opening. The concept is
relatively simple and the vast majority of vessels and piping
with openings conforming to this concept have given
satisfactory service.

There are limits to the applicability of the rules of UG-37. If

the opening size exceeds half the shell diameter and other
conditions specified therein, then supplemental rules of Clause
1-7 need to be applied. The applicability of the rules of Clause
1-7 depend only upon the ratio of the opening diameter to the
shell diameter and appear independent of the absolute size of
each.

E.C. Rodabaugh [2] studied the concept of area replacement

and concluded that in some applications, it could be overly
conservative. He recommended alternate rules which appear as
Clause 1-9 of Appendix 1 in the Code. Application of these FIGURE 1 – TYPICAL BRANCH ON A NOZZLE
rules is however restricted to many conditions specified in
Clause 1-9. It was felt that for small nozzles on small shells, it may not be
really necessary to carry out these additional calculations, so
Subsequently, Clause 1-10 was added in ASME Section VIII this study was undertaken on nozzles having size ranging from
Division 1 which proposed an alternate pressure – area method NPS 2 to NPS 80 when attached to correspondingly larger
for calculation of compensation and could be used in lieu of shells such that the ratio Rn/R did not exceed 0.7.
the rules in UG-37 and Clause 1-7. However, the user was
required to apply U-2(g) for calculation of weld strength paths
which would otherwise have been calculated using the rules in ASSUMPTIONS
UG-41. A pressure-area method is also discussed in WRC
Bulletin 529 [3] which is incorporated in ASME Section VIII As such there may be infinite combinations of nozzle-shell
Division 2 [4]. geometries and pressure. It was therefore necessary to make
some assumptions to make the combinations finite.
Considering the simplicity and widespread use of the rules of
UG-37, it was decided to utilize this method for our study. If it Corrosion Allowance
could be shown that for certain nozzle-shell sizes, the rules of
UG-37 were adequate for nozzle diameter to shell diameter Corrosion allowance was taken as 0.
ratios otherwise requiring calculations to Clause 1-7, it would
minimise the designer’s effort of having to make calculations Nozzle Sizes
to Clause 1-7 also.
Nozzle pipe sizes were taken based on standard pipe sizes as
With the above in mind, a study was undertaken to determine provided in ASME B36.10 [5]. Nominal thickness of the
the absolute size of the nozzle – shell combinations, where the nozzle was used without considering under tolerance. Length
rules of Clause 1-7 would not govern the design even though of nozzle was taken larger than the limit of reinforcement. The
the rules were applicable. The Finite Element Method was nozzle was assumed attached by a full penetration weld to the
used as the referee method. shell.

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 Nozzle Material Both the shell and nozzle were allowed to move radially
outward. SCLs were taken as described in Annex 5-A of
Nozzle material selected was SA 106-B which is a commonly ASME Section VIII Division 2. The resultant stresses were
used carbon steel pipe material for nozzles of pressure vessels. compared with Code allowable values. Figure 3 shows a
typical stress plot. Peak stresses were ignored as these are not
Shell Sizes relevant to the present analysis. Mesh sensitivity review and
global equilibrium check were carried out to validate the
Shell sizes were selected so that nozzle inside radius (Rn) to numerical model as per Clause 2.3.3.1(c)(2)(-h) of ASME
shell inside radius (R) was 0.7. Shell length was kept sufficient Section VIII Division 2.
to provide the required width of reinforcement by the rules of
UG-37.

Shell Material

Shell material could be plate of SA 516-70 for larger nozzles

or pipe of equivalent strength for smaller nozzles. Though in
an actual situation, the arrangement could be of a nozzle of SA
106-B on a larger nozzle of SA 106-B, it was not considered
prudent to introduce this additional variable at this stage.

Weld Material

Weld material was assumed to have properties same as that of

the weaker of the two materials joined, e.g., SA 106-B. In the
Finite Element Analysis, fillet welds were also modelled. The
size of the fillets was calculated in accordance with Figure
UW-16.1 of Code and rounded off to the nearest integer, not
exceeding 9 mm. FIGURE 2(a) – TYPICAL MODEL WITH BOUNDARY
CONDITION USED FOR ANALYSIS
Applied Pressure
If stresses were within limits, then it could be concluded that
Only internal pressure was applied on the nozzle-shell the calculation of P2 was not necessary. If the FEA indicated
geometry. overstress when using P1, it was repeated using the value P2.
If the stresses were acceptable, it could be concluded that
Forces and Moments calculations to Clause 1-7 were required to be carried out for
that nozzle-shell configuration.
Externally applied forces and moments were considered nil.

PROCEDURE

Nozzle sizes and schedules were selected from ASME B36.10

[5], starting from NPS 2 up to NPS 80. The nozzle inside
diameter was then calculated. A shell was then selected having
a radius of (nozzle radius)/0.7 and thickness same as the
nozzle thickness. The MAWP of the shell was then calculated
using the rules of UG-27. Using this value of MAWP, a
pressure P1 was calculated at which the proposed nozzle-shell
configuration met the requirement of UG-37. The rules of
Clause 1-7 were then applied and the permissible pressure P2
was obtained. P2 could be less than or equal to P1.

The elastic stress analysis method as per Clause 5.2.2 of

ASME Section VIII Division 2 using ANSYS FEA software
version 14.5 was used to determine the stresses, using the
FIGURE 2(b) – TYPICAL MESHED GEOMETRY USED FOR
pressure P1. A model was made as shown in Figure 2(a). ANALYSIS USING SOLID 185 ELEMENTS WITH SCLs
Figure 2(b) shows a typical meshed geometry using Solid 185
elements with SCLs. Internal pressure P1 was applied on all
internal surfaces. Axial thrust due to pressure was applied at Figure 3 shows typical stress patterns obtained from Finite
the end of the nozzle. One end of the shell was constrained in Element Analysis.
axial direction and at the other end axial thrust was applied.
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 FIGURE 3 – TYPICAL STRESS PLOT OF NOZZLE-SHELL
GEOMETRY

FIGURE 5 - VARIATION OF PERMISSIBLE PRESSURE FOR

NPS 18 NOZZLE
RESULTS AND DISCUSSION FEA was initially carried out for all nozzle-shell thicknesses in
sizes up to NPS 26. It was observed that highest stresses were
Plots of P1, P2 and P3 were made to illustrate the results of the
obtained for the lowest thickness used for any nozzle-shell
study. It was observed that for nozzles of NPS 4, pressure P2
combination. Subsequently, FEA was restricted to only the
was not less than pressure P1, indicating that the additional lowest nozzle-shell thickness of larger sizes.
calculations of Clause 1-7 need not have been carried out.
Calculations using FEA were not carried out for this case. This As nozzle size was increased to NPS 44 to invoke the
is shown in Figure 4. requirements of Clause 1-7(b), there was a considerable fall in
the permissible pressure P2 when compared to the pressure P1.
The results are shown in the Figure 6. FEA carried out with
the pressure P2a however indicated no overstress. P2b was
therefore conservative.

FIGURE 4 - VARIATION OF PERMISSIBLE PRESSURE FOR

NPS 4 NOZZLE
(Note: P3 Pressure – FEA, not calculated)

For nozzles larger than NPS 4 up to and including NPS 18, it FIGURE 6 – VARIATION OF PERMISSIBLE PRESSURE
was observed that the pressure P2 was lower than the pressure FOR NPS 44 NOZZLE
(Note: P3 Pressure – FEA carried out only for lowest nozzle-shell
P1. However, FEA results indicated that the configuration was thickness)
not overstressed for the pressure P1 and that the pressure P2
was conservative. This is shown in Figure 5.

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 In case of NPS 80 nozzle, using the pressure P2a for FEA, the CONCLUSIONS
assembly was overstressed. However, using the value P2b in
the FEA, the stresses were within allowable limits. The results Study of the need for applying the rules of Clause 1-7 for
are shown in the Figure 7. The use of rules of Clause 1-7(b) openings in cylindrical shells of small diameter indicated the
could now be justified. following:

Data used for plotting the graphs shown in Figures 4, 5, 6 and 1. Openings for nozzles on small shells can be
7 are shown in Table 1. adequately compensated using the rules of UG-37
even though they would fall under the category of
large openings as defined in UG-37(b).

2. Up to and including a nozzle of size NPS 4,

calculations performed using the rules of UG-37 and
Clause 1-7 indicated the same MAWP, so additional
calculations as per Clause 1-7 need not be carried out.

3. Above NPS 4 and up to and including NPS 18,

calculations performed using the rules of Clause 1-7
indicated lower MAWP as compared to calculations
performed using UG-37. Finite Element Analysis
carried out on this geometry indicated however, that
the configuration was not overstressed if the pressure
calculated as per UG-37 was used and therefore this
indicated conservatism in the rules of Clause 1-7,
hence calculations as per Clause 1-7 may not be
required.

4. Above NPS 18, the rules of Clause 1-7 govern the

FIGURE 7 – VARIATION OF PERMISSIBLE PRESSURE design and should necessarily be followed.
FOR NPS 80 NOZZLE
(Note: P3 Pressure – FEA carried out only for lowest nozzle-shell REFERENCES
thickness)
[1] Rules for Construction of Pressure Vessels, Section VIII
Division 1: 2013, The American Society of Mechanical
Engineers.

[2] E.C. Rodabaugh, 1988, “A review of Area Replacement

Rules for Pipe Connections in Pressure Vessels and Piping”,
WRC Bulletin 335

[3] Z. Cao, L. Bildy, D.A. Osage and J.C. Sowinski, 2010,

“Development of Design Rules for Nozzles in Pressure
Vessels for the ASME B&PV Code, Section VIII, Division 2,
WRC Bulletin 529.

[4] Alternative Rules for Construction of Pressure Vessels,

Section VIII Division 2: 2013, The American Society of
Mechanical Engineers.

[5] Welded and Seamless Wrought Steel Pipe, ASME

B36.10M – 2004, The American Society of Mechanical
Engineers

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 Table – 1: DATA USED FOR PLOTTING THE GRAPHS SHOWN IN FIGURES 4, 5, 6 and 7.

Large Openings
Shell
Nozzle Shell
Nominal all. Pressur
Nozzle Nozzle all. Joint Shell wall Shell Pressure Pressure - Pressure - Pressure
wall Stress- e-Shell,
Size OD ID Stress Effici ID thickne OD , UG-37 App 1-7(a) App 1-7b FEA
thickness SA516 UG-27
(mm) (mm) -SA 106 ency (mm) ss (mm) P1(MPa) P2a(MPa) P2b(MPa) P3(MPa)
(mm) 70 P(MPa)
B (MPa) (mm)
(MPa)
NPS 4-STD/40 114.30 6.02 102.26 118.00 1.00 146.09 6.02 158.13 138.00 10.84 6.45 6.45 Not applicable Not calculated

NPS 4-S80/XS 114.30 8.56 97.18 118.00 1.00 138.83 8.56 155.95 138.00 15.85 10.27 10.27 Not applicable Not calculated

NPS 4 - S120 114.30 11.13 92.04 118.00 1.00 131.49 11.13 153.75 138.00 21.21 14.29 14.29 Not applicable Not calculated

NPS 4 - S160 114.30 13.49 87.32 118.00 1.00 124.74 13.49 151.72 138.00 26.42 18.51 18.51 Not applicable Not calculated

NPS 4 - SXXS 114.30 17.12 80.06 118.00 1.00 114.37 17.12 148.61 138.00 35.02 26.03 26.03 Not applicable Not calculated

NPS 18 - STD 457.00 9.53 437.94 118.00 1.00 625.63 9.53 644.69 138.00 4.13 2.22 2.04 Not applicable 2.22

NPS 18 - S30 457.00 11.13 434.74 118.00 1.00 621.06 11.13 643.32 138.00 4.84 2.62 2.42 Not applicable 2.62

NPS 18 - SXS 457.00 12.70 431.60 118.00 1.00 616.57 12.70 641.97 138.00 5.55 3.03 2.82 Not applicable 3.03

NPS 18 - S40 457.00 14.27 428.46 118.00 1.00 612.09 14.27 640.63 138.00 6.26 3.45 3.23 Not applicable 3.45

NPS 18 - S60 457.00 19.05 418.90 118.00 1.00 598.43 19.05 636.53 138.00 8.46 4.79 4.56 Not applicable 4.79

NPS 18 - S80 457.00 23.83 409.34 118.00 1.00 584.77 23.83 632.43 138.00 10.72 6.23 6.03 Not applicable 6.23

NPS 18 - S100 457.00 29.36 398.28 118.00 1.00 568.97 29.36 627.69 138.00 13.41 8.03 7.91 Not applicable 8.03

NPS 18 - S120 457.00 34.93 387.14 118.00 1.00 553.06 34.93 622.92 138.00 16.20 10.00 10.00 Not applicable 10.00

NPS 18 - S140 457.00 39.67 377.66 118.00 1.00 539.51 39.67 618.85 138.00 18.65 11.80 11.80 Not applicable 11.80

NPS 18 - S160 457.00 45.24 366.52 118.00 1.00 523.60 45.24 614.08 138.00 21.61 14.07 14.07 Not applicable 14.07

NPS 44 x 8.74mm 1118.00 8.74 1100.52 118.00 1.00 1572.17 8.74 1589.65 138.00 1.52 0.78 0.69 0.15 0.69

NPS 44 x 9.53mm 1118.00 9.53 1098.94 118.00 1.00 1569.91 9.53 1588.97 138.00 1.66 0.85 0.75 0.17 Not calculated

NPS 44 x 10.31mm 1118.00 10.31 1097.38 118.00 1.00 1567.69 10.31 1588.31 138.00 1.80 0.93 0.82 0.2 Not calculated

NPS 44 x 11.13mm 1118.00 11.13 1095.74 118.00 1.00 1565.34 11.13 1587.60 138.00 1.95 1.00 0.89 0.23 Not calculated

NPS 44 x 11.91mm 1118.00 11.91 1094.18 118.00 1.00 1563.11 11.91 1586.93 138.00 2.08 1.08 0.95 0.26 Not calculated

NPS 44 x 12.7mm 1118.00 12.70 1092.60 118.00 1.00 1560.86 12.70 1586.26 138.00 2.22 1.15 1.02 0.29 Not calculated

NPS 44 x 14.27mm 1118.00 14.27 1089.46 118.00 1.00 1556.37 14.27 1584.91 138.00 2.50 1.30 1.16 0.36 Not calculated

NPS 44 x 15.88mm 1118.00 15.88 1086.24 118.00 1.00 1551.77 15.88 1583.53 138.00 2.79 1.45 1.30 0.43 Not calculated

NPS 44 x 17.48mm 1118.00 17.48 1083.04 118.00 1.00 1547.20 17.48 1582.16 138.00 3.08 1.61 1.45 0.51 Not calculated

NPS 44 x 19.05mm 1118.00 19.05 1079.90 118.00 1.00 1542.71 19.05 1580.81 138.00 3.36 1.76 1.59 0.6 Not calculated

NPS 44 x 20.62mm 1118.00 20.62 1076.76 118.00 1.00 1538.23 20.62 1579.47 138.00 3.64 1.92 1.74 0.68 Not calculated

NPS 44 x 22.23mm 1118.00 22.23 1073.54 118.00 1.00 1533.63 22.23 1578.09 138.00 3.93 2.08 1.89 0.78 Not calculated

NPS 44 x 23.83mm 1118.00 23.83 1070.34 118.00 1.00 1529.06 23.83 1576.72 138.00 4.22 2.25 2.04 0.88 Not calculated

NPS 44 x 25.4mm 1118.00 25.40 1067.20 118.00 1.00 1524.57 25.40 1575.37 138.00 4.51 2.41 2.20 0.98 Not calculated

NPS 44 x 26.97mm 1118.00 26.97 1064.06 118.00 1.00 1520.09 26.97 1574.03 138.00 4.79 2.57 2.35 1.09 Not calculated

NPS 44 x 28.58mm 1118.00 28.58 1060.84 118.00 1.00 1515.49 28.58 1572.65 138.00 5.09 2.74 2.52 1.2 Not calculated

NPS 44 x 30.18mm 1118.00 30.18 1057.64 118.00 1.00 1510.91 30.18 1571.27 138.00 5.38 2.91 2.68 1.32 Not calculated

NPS 44 x 31.75mm 1118.00 31.75 1054.50 118.00 1.00 1506.43 31.75 1569.93 138.00 5.67 3.08 2.84 1.44 Not calculated

NPS 80 x14.27mm 2032.00 14.27 2003.46 118.00 1.00 2862.09 14.27 2890.63 138.00 1.37 0.69 0.61 0.12 0.12

NPS 80 x15.88mm 2032.00 15.88 2000.24 118.00 1.00 2857.49 15.88 2889.25 138.00 1.52 0.78 0.68 0.15 Not calculated

NPS 80 x17.48mm 2032.00 17.48 1997.04 118.00 1.00 2852.91 17.48 2887.87 138.00 1.68 0.86 0.75 0.18 Not calculated

NPS 80 x19.05mm 2032.00 19.05 1993.90 118.00 1.00 2848.43 19.05 2886.53 138.00 1.83 0.94 0.83 0.21 Not calculated

NPS 80 x20.62mm 2032.00 20.62 1990.76 118.00 1.00 2843.94 20.62 2885.18 138.00 1.98 1.02 0.90 0.24 Not calculated

NPS 80 x22.23mm 2032.00 22.23 1987.54 118.00 1.00 2839.34 22.23 2883.80 138.00 2.14 1.10 0.98 0.27 Not calculated

NPS 80 x23.83mm 2032.00 23.83 1984.34 118.00 1.00 2834.77 23.83 2882.43 138.00 2.30 1.18 1.05 0.31 Not calculated

NPS 80 x25.4mm 2032.00 25.40 1981.20 118.00 1.00 2830.29 25.40 2881.09 138.00 2.45 1.27 1.13 0.35 Not calculated

NPS 80 x26.97mm 2032.00 26.97 1978.06 118.00 1.00 2825.80 26.97 2879.74 138.00 2.60 1.35 1.20 0.38 Not calculated

NPS 80 x28.58mm 2032.00 28.58 1974.84 118.00 1.00 2821.20 28.58 2878.36 138.00 2.76 1.44 1.28 0.43 Not calculated

NPS 80 x30.18mm 2032.00 30.18 1971.64 118.00 1.00 2816.63 30.18 2876.99 138.00 2.92 1.52 1.36 0.47 Not calculated

NPS 80 x31.75mm 2032.00 31.75 1968.50 118.00 1.00 2812.14 31.75 2875.64 138.00 3.07 1.61 1.44 0.51 Not calculated

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