Design of Pressure Vessel for Nozzle Attachment Using Structural Analysis

Name: Sandeep Sakharam Patil, Ph.D. Research Scholar, Department of Mechanical Engineering, SJJT
University. Rajasthan, India

Registration Number - 24121011

Email ID: [email protected]

Guide – Dr. Nitish Kumar Gautam, Assistant Professor, Department of Mechanical Engineering,
JJT University, Rajasthan, India
Co Guide – Dr.R.J.Patil, Principal, Navasahyadri Educations Society's, Group of Institution,
Faculty of Engineering, Pune.
Affiliating Organization: Shri J J T University, Rajasthan.
Date: 22-Dec-2022

Abstract:-
Pressure vessels require nozzles for input and output functions. These nozzles shouldn't disrupt
the vessel's symmetry if they are located on the dish's peak. Nonetheless, there are times when a
method necessitates placing nozzles outside the pressure vessel. These nozzles cause the vessel's
symmetry to be off. Nozzle connectors' geometrical dimensions might vary greatly, even inside a
same pressure vessel. These nozzles break the geometric continuity of the vessel wall. The area
next to the entrance becomes strained as a result. The connection can break under these intense
stresses.
Hence, a careful analysis is required. The system's axis symmetry is broken when nozzles are
placed on the edge of a pressure vessel, which causes eccentricity. An imbalance in the structure
and the generation of a couple are occasionally the outcomes of this. The existence of the nozzle
will stop the structure's radial expansion. Here, we'll concentrate on the fixed end of the nozzle
that is fastened to an assembly. An eccentricity will occur if there is only one nozzle; what will
happen if there are more nozzles? then to ascertain how that situation may effect system stresses.
It must be investigated in FEA in order to understand how the nozzle affects the vessel's stress
characteristics..
Key Words:-
Hexahedron & Tetrahedron meshing, Non Linear Finite Element Analysis, Nozzle Junction,
Monotonic Convergence, Pressure Vessel.
 1. Introduction:-
Several industrial sectors, such as the production of chemical and petroleum-based
machinery, nuclear and power engineering, the gas, oil, and oil-refining industries, aerospace
technology, etc., heavily rely on the use of pressure vessels. As the name implies, these are
essential components of processing equipment. Nozzles or openings are necessary for the
pressure vessels to meet requirements such as inlet or outlet connections, manholes, vents &
drains, etc. The cylindrical shell and heads of pressure vessels can both contain welded nozzles
that connect the vessel to piping. [1-2].
Nozzle connectors' geometrical dimensions might vary greatly, even inside a same pressure
vessel. These nozzles break the geometric continuity of the vessel wall. The area next to the
entrance becomes strained as a result. These severe strains have the potential to destroy the link.
Consequently, a thorough analysis is needed. The stress study of two intersecting shells is one of
the components of the overall structural investigation for nozzle connections. [4, 6].
A local stress state of the nozzle connection that is characterized by high stress concentration
arises at the intersection region as a result of the different loadings that these structures are
subjected to. Internal pressure is the main loading used in the structure analysis to select the main
vessel-nozzle connections. The impact of external forces and moments applied to the nozzle
should be taken into account in addition to the stresses caused by the internal pressure. The bulk
of the time, external loading is imposed by a pipe system that is connected to the nozzle. The
loads and moments are calculated using a study of the pipe system. [9].
Many studies, including analytical, experimental, and numerical ones, have looked at the
stress study of nozzle connections in pressure vessels that have experienced different external
loadings. The rules provide a technique for building the junction but no formula for figuring out
how long and how much these high stresses will amplify. Only straightforward geometries have
an analytical solution. WRC-107 backs [5-8]. To ascertain the stresses at the junction as well as
in the vessel and nozzle, a full finite element analysis of the junction is necessary. the ANSYS
suite being used as a finite element tool [11].

1.1 Scope for the work:

1) Eccentricity is caused when nozzles are placed outside of a pressure vessel because they throw
off the system's axis symmetry.
2) This quirk occasionally might give birth to a couple, which might cause a structural issues.
3) Radial type of nozzle will prevent the structure from expanding radially. Here, we'll
concentrate on the fixed end of the nozzle that is fastened to an assembly.
4) An eccentricity will occur if there is only one nozzle; what will happen if there are more
nozzles? then to ascertain how that situation may effect system stresses.
 Fig. 1 - Sketch of Pressure Vessel

1.2 Demand for FEA

1) In order to avoid catastrophic failure due to stress-related vessel rupture, it is crucial to
identify the main factors that lead to stress generation in pressure vessels and how to reduce
them.
2) Although though the nozzles are positioned in various places, such as the dish end, side, etc.,
the ASME code gives a design formula for pressure vessels with nozzles. However neither
installing nozzles at the same height nor reducing the effects of stresses are specifically
mentioned in the ASME code.
3. These are a very recent invention, having only been created in 2003 for Quench Nozzles
particularly. Thus, there is no data from standardized exams about them. As a result, the only
option is the Design by Analysis strategy advised by ASME.

1.3 Objective:
1) To calculate the stresses at the junction where the pressure vessel and the nozzle meet, a finite
element analysis of the junction is performed using ANSYS software. The effects of the nozzle's
existence on the pressure vessel design are examined through analysis.
2) Analysis is done for pressure vessels with peripheral nozzles to find out how much stress is in
the pressure vessel and nozzle and how much stress is present when the nozzle is present.
3) To add more nozzles to a pressure vessel while running an ANSYS structural analysis.
4) Check the stress level after adjusting the angle between the nozzles to examine the impacts of
nozzle location.
5) Choose the ideal angle to keep the strains within acceptable limits.
6) To validate the results, mesh sensitivity analysis should be performed on all FEA models. As
the analysis' mesh size fluctuates, the so-called "Mesh Sensitivity Analysis" takes place.
 2. Basic element shapes
We can idealize the body by employing the three-dimensional components in figure 2.1 if the
geometry, material qualities, and other aspects of the body can be expressed by three separate
spatial coordinates.

Fig.: 2.1 3D finite elements.

Curved-side finite elements are useful for discretizing problems with curved geometries. The
modeling of curving borders has been made possible with the inclusion of midsized nodes. In
contrast to linear elements, which have straight sides, higher order elements are defined as finite
elements having curved sides.
2.1 Elements' Size:
Careful consideration must be given to the size of the elements because it directly impacts the
convergence of the solution. If the size of the elements is small, then the final result should be
more precise.
2.2 Number of Elements:
The number of idealized elements should be determined by the degree of accuracy necessary, the
size of the elements, and the overall number of degrees of freedom. Even though adding more
elements often yields more accurate answers, there will always be a certain number beyond
which accuracy cannot be significantly improved for any given problem. This tendency is
illustrated graphically in Fig. 2.2.
 Fig.2.2 Number of elements and the accuracy.

3. Static structural analysis:

The load or field conditions in a static structural analysis are applied gradually, and they don't
alter over time. Three formal requirements must be met by any stress analysis: force (or stress)
equilibrium, displacement compatibility, and satisfaction of the stress state at continuum
boundaries. The employment of force, pressure, inertia, heat, and defined displacements are just
a few other sorts of loads. It's crucial to remember that before the other displacements can be
calculated, at least one of them must be known. The boundary conditions, also known as the
known displacements, are typically zero.

3.1 Analytical Methodology:

1) Examining the static structural components of the press. Vessels for various models are to be
made using the "ANSYS WORKBENCH." The following is a list of pressure vessel models with
nozzle attachments that can be analyzed:

Table No. 3.1 List of Different Model

2) Adjust the angle between the nozzles in the vessel using static structural analysis. We must
determine the appropriate angle to keep the stresses within allowable limits since the closer the
two nozzles are together, the more contact between their stress zones will occur.
3) To accomplish convergence or boost the analysis's precision, the vessel, nozzle, and nozzle
pad's element sizes are modified regularly. That is, there will be more elements.
4) For each model, all of the aforementioned analysis for the four various element sizes must be
conducted while following to the set constraints, utilizing two different meshing techniques. i.e.,
two different element shape kinds are subjected to the same examination (mesh)
i) Hex dominant meshing
ii) Tetrahedron meshing

Table No. 3.2 Element Size for parts

Total approx. number of analysis runs: 125

3.2 Inputs for FEA :

A. Design Data:
Design Code: ASME Section VIII Div. 2 Design Pressure: 0.25 MPa = 0.25 ×106 Pa = 2.5 N/m2
Reference Temperature: 200 C Material: structural steel
B. Geometry:
Vessel ID: 1160 mm Shell Thickness: 70 mm Length of Vessel: 6250 mm Pad ID: 285 mm Pad
OD: 570 mm Pad Thickness: 70 mm Nozzle ID: 150 mm Nozzle Thickness: 60 mm Nozzle
Height (total): 450 mm Nozzle Head Dia.: 550 mm Nozzle Head Thickness: 47 mm
C. Material Data:
Following are the Material properties for Structural steel:
 Table No.3.3 Material Property

D. Mechanical Boundary Conditions

1. Internal Pressure: 0.23 N/mm2
2. Displacement:

Table No.3.4 Displacement

3.3 Analysis of pressure vessel with number of nozzle = 3 & angle=1000 :

1) to carry out structural analysis and identify stress circumstances at the nozzle connection of
the vessel.
2) The convergence test for the model is examined by increasing the number of structural
analysis parts.
i) Analysis System:
In our situation, we must identify both the overall pressure vessel stress and the stress in the
region of the nozzle attachment. Hence, the pressure being applied stays constant. Because there
is no variation with respect to time (df/dt = 0), the analytic system can be regarded as static
structural (ansys).
ii) Model:
Only the region where the nozzle connection to the rim of the pressure vessel should be
calculated. With different nozzle numbers and angles, we have a variety of pressure vessel
models.
iii) Meshing Method:
We are retaining the same element size for the press vessel model while utilizing both hex and
tetra meshing.

Fig.3.1 Hexahedron elements & Tetrahedron elements

v) Structural Analysis:
Need to provide the model a boundary condition or constraint at this stage. Vessel shall be tested
at the pressure of 0.25 MPa, this pressure was chosen with internal pressure.

4. Findings and Discussion:

According to the study's findings, the pressure vessel and nozzle's intersection is where stress is
produced to the greatest degree. Because of the quick change in geometry and the resulting
alteration in stress flow, this area is under a lot of stress.

4.1 Solution:
The next steps are mesh construction and boundary condition application. For the complete
pressure vessel, including pads 1 and 2, the equivalent stress (Von-Mises stress) and total
deformation are calculated.
i) Maximum overall deformation
The pressure vessel's maximum deformation is 9.7518 10 (-5) m.

ii) Overall Equivalent Stress:

Minimum Deformation in a Pressure Vessel is 7.7107 10 (-8) m. The pressure vessel's maximum
equivalent von mises stress is 6.2765 106 Pa, or around 6.2765 MPa.
 Fig. 4.1 overall max.equivalent stress

iii) Equivalent Stress of Pad 1:

Fig. 4.2 equivalent stress of pad 1

The pressure vessel's max. equivalent Von Mises stress is 2.9423 × 106 Pa, which is
approximately 2.9423 MPa
iv) Equivalent Stress pad on 2:
Max. Equivalent Von Mises Stress in the Pressure Vessel is 3.1854 × 106 Pa, which is
approximately 3.1854 MPa
v) Stress at nozzle attachment area:
Figure shows that the area of nozzle attachment is under the most stress. The highest possible
equivalent Von-Mises stress is 6.32 × 106 Pa
4.2 Result of Two Nozzle & Angle=950:

Table No. 4.1 Result of nozzle.=2 angle=950

4.2.2 Tetrahedron Meshing:

i) Max. Stress (with tetra mesh):
Stress is increasing and is advancing to 6.13× 106 Pa.

Fig.4.3 Max. Stress (using tetra Mesh)

ii) Maximum stress for tetrahedral meshing on pads 1 and 2:

Stress accumulating toward a value of 3.43 × 106 Pa for pad 1.
Stress accumulating toward a value. of 3.44 × 106 Pa for pad 2

Fig. 4.4 Max. Stress on Pads 1 & 2 (for Tetra Meshing) graph

4.3 Results of Peak Stresses from all cases :

Table No. 4.2 Result of peak stresses

The peak stresses of the pressure vessel as a whole and in the pad where the nozzle is attached
are shown in the table below.
Peak stress results can be compared, and the case has the least amount of stress N2/180 & N4/90
4.4 Factor of Increased Nozzle Stress (N):

The definition of the Stress Increment Factor for a certain scenario is

N= (Peak stress for the case under consideration / Peak stress for a single nozzle)
e.g. N2/60 =(4.45E+06) / (4.21E+06) =1.0673

Table No. 4.3 Nozzle Stress Increment Factor

We can infer from looking at the table of the nozzle stress increment factor that the stress
increment factor for N2/180 & N4/90 is low.
5. Conclusion:
1. If higher order components are not included, the mesh choice has a major impact on the
accuracy of the FE model. A finer mesh will typically yield more accurate readings than a coarse
mesh. The point of diminishing returns is the point at which increasing the mesh density no
longer significantly affects the results. The mesh is said to have "converged" at this stage. Mesh
convergence is still the most trustworthy method for evaluating model accuracy..
2. As the mesh is enhanced, convergence is clearly demonstrated for all of these models. Our
results show that monotonic convergence is more reliable than oscillatory convergence. In
general, adding more nodes and elements improves the accuracy of the results.
3. The maximum stress values are obtained from the examination of all load scenarios.
According to the study's findings, the pressure vessel and nozzle's intersection is where stress is
produced to the greatest degree. A high stress concentration forms here as a result of an abrupt
change in the geometry and the resulting change in stress flow.
4. The symmetrical nozzle attachment has the lowest peak stress in comparison to the other
asymmetrical examples.
5. The stress increment factor for the symmetrical nozzle attachment is lower than that of the
other attachments.
6. Yet, given our data, we can conclude that symmetry is a much more important feature than the
number of nozzles.
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