NUCLEAR ENGINEERING AND DESIGN 7 (1968) 73-86.

NORTH-HOLLAND PUBLISHING COMPANY, AMSTERDAM

EXPERIMENTAL ELASTIC STRESS ANALYSIS

OF PARTIAL PENETRATION WELDED NOZZLES
IN A SPHERICAL SHELL
E. P R O C T E R

and R. F. F L I N D E R S

Central Electricity Generating Board,

Berkeley Nuclear Laboratories,
Berkeley, Glos., England
Received 12 May 1967

The initial stage of a test programme to investigate, in detail, the behaviour of radial and oblique
nozzle junctions in spherical shells, has been completed. Although this stage was designed to investigate elastic and elastic/plastic behaviour at ambient temperature, this report describes the elastic
analysis only.
Three basic designs of through nozzles were investigated, one of each design mounted radially and
the other at 45 obliquity. Four hundred E.R. strain gauges were fixed on the inner and outer surfaces
of the shell plate and nozzles and optical equipment was set up to measure tilt of the nozzles. For the
purpose of this elastic test the vessel was hydraulically pressurized to 240 psig.
Stress distributions in the form of stress concentration factors (SCF = stress magnitude divided by
the corresponding stress in an unpiereed sphere of the same radius and thickness) are shown for the
individual nozzles. Maximum values of SCF and 'equivalent' stress are shown plotted against the ratio
of nozzle thickness to nozzle internal diameter, for both radial and oblique cases.
Comparisons are made with nozzles designed according to BS.1500 and BS.3915, and the limitations
of elastic design methods allowing limited plasticity are demonstrated and discussed in the report.

1. INTRODUCTION
O p e r a t i o n a l i n f o r m a t i o n of p r e s s u r e c i r c u i t
c o m p o n e n t s on n u c l e a r and m o d e r n high e f f i c i e n c y
conventional plant i s s t i l l e x t r e m e l y l i m i t e d .
E a r l y work at B e r k e l e y N u c l e a r L a b o r a t o r i e s ,
on m o d e l v e s s e l s containing standpipe n o z z l e
c l u s t e r s and cylindrlLcal s u p p o r t s k i r t s , p r o v i d e d
a b a s i c u n d e r s t a n d i n g of g e o m e t r i c a l e f f e c t s on
v e s s e l s s u b j e c t e d to p r e s s u r e alone and p r e s s u r e
and t e m p e r a t u r e combined. H o w e v e r , in o r d e r to
modify e x i s t i n g p a r a m e t e r s to a c h i e v e m o r e
e c o n o m i c a l d e s i g n s ,.and to p r e d i c t m o r e a c c u r a t e l y
the working life of e x i s t i n g n u c l e a r plant, c o m p o nents m u s t be studied in g r e a t e r d e ta il .
Throughout the C e n t r a l E l e c t r i c i t y G e n e r a t i n g
B o a r d much e f f o r t is being e m p l o y e d in t h e o r e t i c a l
s t u d i e s to i m p r o v e the design of p r e s s u r e containing s t r u c t u r e s . The.,~e s t u d i e s take into account
long t e r m c r e e p b e h a v i o u r at e l e v a t e d t e m p e r a t u r e s as well as sho:ct t e r m and c y c l i c e l a s t i c /
plastic considerations. Through these efforts
solutions f o r s y m m e t r i c a l a t t a c h m e n t s a r e b e c o m i n g a v a i l a b l e . It w il l, h o w e v e r , be s o m e t i m e
b e f o r e a s y m m e t r i c p r o b l e m s can be solved.

Detailed experimental results are, therefore,

r e q u i r e d f o r two m a i n r e a s o n s :
1) V e r i f i c a t i o n of t h e o r e t i c a l solutions.
2) P r e d i c t i o n of the b e h a v i o u r of t y p i c a l c o m p o nents which cannot at p r e s e n t be t h e o r e t i c a l l y
an al y sed , a s s i s t i n g both d e s i g n e r s of future
plant and o p e r a t o r s of e x i s t i n g plant.
In o r d e r to obtain a m a x i m u m amount of i n f o r mation with r e s p e c t to t h e s e r e q u i r e m e n t s , a
s e r i e s of t e s t s has been i n i t i a t e d to i n v e s t i g a t e
both s h o r t and long t e r m b e h a v i o u r of t y p i cal
n o z z l e / s h e l l i n t e r s e c t i o n s . Two d e s i g n s r e p r e s e n t a t i v e of e x i s t i n g plant, and a t h i r d design,
n o m i n a l l y p r e s s u r e s t r e n g t h , to p r o v i d e a datum
and an indication of v e r y high s t r a i n b e h a v i o u r
a r e b ei n g t e s t e d . F r o m each design, one n o z z l e
is mounted r a d i a l l y and a second at 45 obliquity.
Although the v e s s e l and n o z z l e s r e p r e s e n t c u r r e n t r e a c t o r v e s s e l s i z e s , the r e s u l t s a r e , of
c o u r s e , applicable to o t h e r t y p e s of v e s s e l s .
The f i r s t t e s t of the s e r i e s was d e s i g n e d
p r i m a r i l y to i n v e s t i g a t e s h o r t t e r m e l a s t i c / p l a s t i c b e h a v i o u r , with p a r t i c u l a r attention being
paid to shakedown e f f e c t s and the e x t e n s i o n of
s t r e s s d i e - a w a y as p l a c t i c i t y p r o c e e d s . A l so ,

74

E. PROCTER and R. F. FLINDERS

since v i r t u a l l y no e x p e r i m e n t a l data is available

for single through n o z z l e s with p a r t i a l p e n e t r a tion welds, a full e l a s t i c s t r e s s a n a l y s i s has
been c a r r i e d out. Special attention was paid to
the d i s t r i b u t i o n of s t r e s s in the shell plate a d j a cent to a r a d i a l l y mounted nozzle. This p a r t of
the work is d e s c r i b e d in this r e p o r t .

2. DESCRIPTION OF TEST VESSEL AND

NOZZLES

2.1. Materials
The behaviour of the v e s s e l beyond y i e l d is
influenced by the p h y s i c a l p r o p e r t i e s of the m a t e r i a l s as well as component g e o m e t r y . If comp a r i s o n s a r e to be made with the full size prototype it is d e s i r a b l e to obtain c o r r e c t r e l a t i o n s h i p
between the v a r i o u s m a t e r i a l s , i . e . , shell plate,
nozzle forgings and deposited weld. In the case
of i n v e s t i g a t i o n s into creep behaviour this r e l a tionship is also d e s i r a b l e , together with the
ability to a c c u m u l a t e c r e e p s t r a i n in r e a s o n a b l y
short test d u r a t i o n s .
The m a t e r i a l chosen for the t e s t p l a t e s was
b o i l e r plate to BS 1501(1958)-161-C and for the
n o z z l e s , forged b a r to BS 1503(1958)-161-B.
Standard t e n s i l e s t r e n g t h r e q u i r e m e n t s for both
these m a t e r i a l s a r e 28 t s i rain., 32 t s i max.
Yield s t r e s s r e q u i r e m e n t s are b a s e d on m i n i m u m
v a l u e s only, 15 t s i for the plate m a t e r i a l and
14 t s i for forged b a r . To obtain s i m i l a r i t y of
p h y s i c a l p r o p e r t i e s in the t e s t v e s s e l an upper
l i m i t of 18 tsi was specified for both plate and
forged m a t e r i a l s .
The m a n u f a c t u r e r s ' a n a l y s i s for the two m a t e r i a l s was as given in table 1.
Table 1

C
Si
S
Ph
Mn
Ni
Cr
Mo
Cu
YP
UTS
Elongation
Reduction
of area

Plate
to BS1501(1958)161-C

Forged bar
to BS1503(1958)161-B

0.22%
0.2%
0.02%
0.024%
0.78%
0.1%
0.08%
0.01%
0.12%
17.7 tsi
31.4 tsi
24% on 8 in.
gauge length

0.21%
0.233%
0.038%
0.028%
0.72%

17.15 tsi
31.9 tsi
35~0 on 4~A
61%

2.2. Nozzle weld procedures

To obtain r e a s o n a b l e r e p r e s e n t a t i o n of the
nozzle welds on the model to those on full size
v e s s e l s , suitable weld p r o c e d u r e s had to be
developed. P r e l i m i n a r y work was c a r r i e d out at
the C . E . G . B . ' s N.W. Region R. & D. Department,
u s i n g flat plates with edge p r e p a r a t i o n s r e p r e sentative of the v a r i o u s weld conditions. As a
r e s u l t of this work, tentative weld p r o c e d u r e s
were suggested to the v e s s e l m a n u f a c t u r e r .
The m a n u f a c t u r e r s s u b m i t t e d s e c t i o n s through
at least one each of the oblique n o z z l e s , to show
that the specified r e q u i r e m e n t s could be met.
P a r t i c u l a r attention was paid to the h a r d n e s s and
width of heat affected zones, the h a r d n e s s of the
deposited weld m a t e r i a l and the a n g u l a r t o l e r ances.
2.3. Manufacture
The n o z z l e s were positioned in the v e s s e l
such that e l a s t i c s t r e s s i n t e r f e r e n c e between
n o z z l e s was nil. Nozzle s e c t i o n s a r e shown in
figs. 1-3.
Fig. 1 shows the thickest p a i r of n o z z l e s fitted
in the v e s s e l . These a r e n o m i n a l l y true to scale
of r e a c t o r v e s s e l standpipe n o z z l e s designed to
BS1500, in which design all r e i n f o r c e m e n t for
the opening in the shell plate is provided by the
nozzle. Fig. 2 shows n o z z l e s r e p r e s e n t a t i v e of
r e a c t o r v e s s e l standpipe a t t a c h m e n t s , designed
to BS1500, but where the whole of the upper p a r t
of the v e s s e l is made in t h i c k e r plate than r e q u i r e d by n o r m a l m e m b r a n e s t r e s s c a l c u l a t i o n s ,
i.e., p a r t r e i n f o r c e m e n t for the openings i s p r o vided by the nozzle and p a r t by the use of thicker
shell plate. Fig. 3 shows the final p a i r of n o z z l e s .
It was d e s i r e d to design these on a p u r e p r e s s u r e
s t r e n g t h b a s i s , i.e., nozzle t h i c k n e s s 0.035 in.
Owing to obvious welding p r o b l e m s the n o z z l e s
were made ~ in. thick. The r a d i a l nozzle is
s l i g h t l y thicker than that r e q u i r e d by BS3915
(t = 0.07 in.) and the oblique nozzle slightly thinn e r (BS3915, t = 0.21 in.).
Care was taken before and d u r i n g m a n u f a c t u r e
to e n s u r e that t o l e r a n c e s would be r e p r e s e n t a t i v e ,
at this scale, of r e a c t o r p r a c t i c e . The development
t e s t s indicated that the angles of the oblique nozzles could be m a i n t a i n e d within +2 . In the t e s t
v e s s e l the m a x i m u m deviation f r o m n o m i n a l was
1. The test plate p r o f i l e was checked by t e m plates. The m a x i m u m deviation f r o m t r u e shape,
m e a s u r e d over a 4 ft chordal length was 0.050 in.,
and over a 1 ft chordal length 0.025 in. These
t o l e r a n c e s a r e well within acceptable l i m i t s ,
even when c o n s i d e r i n g the scale factor. The nozzles were machined to an a c c u r a c y of +0.005 in.

EXPERIMENTAL ELASTIC STRESS ANALYSIS

75

-125~

N O Z Z L E . 2,.

f
"

=oo,,

.328~

&
W

I
,3211"

~]

"687"

/ / ~

2.87

//
NOZZLE

5.

= 0'287
NOZZLE 4,

r",'//i//'///

t/T

~ !:

0-0148

~t=

0,I14

= 0.603

~Di = 0"0148
~"/~i = 0239

Fig. 1. Section through nozzles 1 and 4.

on d i a m e t e r . Two holes, ~ in. d i a m e t e r were
d r i l l e d through each nozzle wall and located b e tween the i n n e r and outer filled welds (see figs.
1-3). These were to f a c i l i t a t e leak t e s t s on the
root r u n s . Any flaw:3 allowing leakage r a t e s
g r e a t e r than 1 cusec', were r e p a i r e d before f u r t h e r welding. After completion, the nozzle welds
were u l t r a s o n i c a l l y e x a m i n e d with the aid of
automatic s c a n n i n g equipment supplied and
o p e r a t e d by p e r s o n n e l f r o m C.E.G.B S.W. Region
R. & D. A t h i c k n e s s s u r v e y on the t e s t plate at
3 in. pitches, indicated t h i c k n e s s v a r i a t i o n s b e tween 1.125 in. and :1.135 in.

Fig. 2. Section through nozzles 2 and 5.

3. INSTRUMENTATION
3.1. Slrain gauges
The s t r a i n gauges used were Budd type HE 121,
having ~ in. gauge length and 120~ n o m i n a l r e s i s t a n c e . L a b o r a t o r y t e s t s d e m o n s t r a t e d these
gauges to be s a t i s f a c t o r y for m e a s u r i n g s t r a i n s
up to at l e a s t 7% when used with Budd type GA 5
adhesive [1].
The total n u m b e r of gauges was r e s t r i c t e d to
400, by the capacity of the r e c o r d i n g equipment.
The m a j o r i t y were fixed on n o z z l e s and s u r rounding plate, in positions chosen to provide

E. PROCTER and R. F. FLINDERS

76

NOZZL__E _3
t/T

- 0"11

L~/D. = 0"0148

~/~( - 0"0434

"125"
"25~

","
Ux
S"
j/
M ~

/ , 4s'~
//

~-~,..~I

NOZZLE 6
~/T

"

%~ =

INSIDE H OOP/CIRC.
X OUTSIDE HOOP/CIRC,
-p
Q O~u'l"SIDE A XlAL/~4EI~I

1 ~

--

"%-/

O'"
0.0,48

2"0

1"O

-I,O

S.C.F.

Fig. 3. Section through n o z z l e s 3 and 6.

LIGHT SOURCE PROJECTING

CROS5 WIRE IMAGE,

OPTICALLY FLAT
MIRROR .~.~ " ~ /

RECTANGULAR SCALE.

Fig. 4. Diagrammaticarrangementof optical lever

system.

Fig. 5. S t r e s s d i s t r i b u t i o n s for radial nozzle (No. 1).

the most economical distribution with due consideration of the information required. Gauges
were provided on both the inner and outer surfaces of the vessel and the nozzles. Since high
strain gradients were expected inside the nozzles, particular care was taken to position
gauges at the expected maximum strain positions. Gauge positions are shown on the stress
plots in figs. 5-7 and 16-18. The gauges were
fixed inside the nozzles by an expanding mandrel
technique [2].
All strain gauges were connected to intermediate junction boxes by light-gauge double
insulated twin core cable. Multi-core cables
were used for the lead outs from these junction
boxes to the permanent strain recording equipment. The multi-core cables from inside the
vessel were brought through rubber packed sealing glands [3] in the end flanges of the two I0 in.
bore branches.

T h e v e s s e l w a s to b e p r e s s u r i z e d

EXPERIMENTAL ELASTIC STRESS ANALYSIS

HOOP/CIRC.

INSIDEHOOP/CIRC,
X OUTSIDEHOOP/CIRC.
e OUTSI
INSIDE
DI.~AXIAL/tVlERID.
AXIAL/MERi D.

77

GAUGE6

~+

,.I-

S.C.F_~_

HOOP /CIRC.
't" AXIAL/MERID.
S.C.F'S.
INSIDE HOOP/CIRC.
X OUTSIDEHOOP/CIRC.
1- IN$10E AXlAL/MERID.

-t

S.C.F.

Fig. 6. Stress distributions for radial nozzle (No. 2).

Fig. 7. Stress distributions for radial nozzle (No. 3).

with w a t e r , thus the i n t e r n a l g a u g e s and junction

b o x e s w e r e w a t e r p r o o f e d with a b i t u m a s t i c c o m pound [4].
Since the s t r a i n g a u g e s w e r e all fixed to a
c o m p a r a t i v e l y s m a l l a r e a of the t e s t v e s s e l ,
which i t s e l f was f i l l e d with w a t e r , one c o m p e n sating gauge only was used. This was attached
to a plate of the s a m e m a t e r i a l as the v e s s e l ,
w a t e r p r o o f e d and p l a c e d in a d r u m of w a t e r
a lo n g s i d e the v e s s e l . To p r o v i d e a check on z e r o
gauge d r i f t one f u r t h e r gauge was a t t a c h e d to a
f r e e plate, w a t e r p r o o f e d and p o s i t i o n e d i n s i d e
the v e s s e l and c o n n e c t e d to the r e c o r d i n g equipm e n t t o g e t h e r with the a c t i v e gauges. The r e c o r d i n g eq u i p m en t e m p l o y s a digital v o l t m e t e r
with v i s u a l display and an a s s o c i a t e d p r i n t - o u t
unit.

of each n o z z l e and, to p r o v i d e a datum, to the

c e n t r e of the t e s t plate. Individual p r o j e c t i o n
l a m p s w e r e u s e d to r e f l e c t a c r o s s - w i r e i m a g e
on to s c a l e s a p p r o x i m a t e l y 8 ft below the m i r r o r s , a s shown in fig. 4. Closed c i r c u i t t e l e v i sion was u s e d to p r o v i d e a v i s u a l link between
the t e s t c e l l and c o n t r o l a r e a , thus enabling
n o z z l e r o t a t i o n s to be r e c o r d e d r e m o t e f r o m the
vessel.

3.2. Nozzle deflections

Nozzle r o t a t i o n s o r t il t, r e l a t i v e to the t e s t
p l a t e , w e r e m e a s u r e d by an o p t ic a l l e v e r s y s t e m .
An o p t i cal l y flat m i r r o r was attached to the end

4. T E S T P R O C E D U R E
At z e r o p r e s s u r e all gauges w e r e individually
b a l a n c e d to indicate z e r o output f r o m the wheatstone b r i d g e c i r c u i t . To e l i m i n a t e the p o s s i b i l i t y
of gauge h y s t e r e s i s the v e s s e l was p r e s s u r e
c y c l e d s e v e r a l t i m e s between z e r o and 250 psig.
Gauge r e a d i n g s and n o z z l e c r o s s - w i r e r e a d i n g s
w e r e then r e c o r d e d at 40 p si i n c r e m e n t s f r o m
z e r o p r e s s u r e to 240 p s i g and r e t u r n e d to z e r o .
V e s s e l p r e s s u r e was i n d i cat ed by a s t a n d a r d
10 in. t e s t gauge.

78

E. PROCTER and R. F. FLINDERS

MEAN STRESS.

x\
x.

...e...- - - f
o

l
i
05

Fig. 8. Stress concentration factors inside radial nozzles.

Maximum hoop SCF's
+ Axial SCF's at maximum hoop positions
Q Maximum axial SCF's

,Io

20

.2Is

Fig. 9. Maximum stress concentration factors for shell

plate (radial nozzles).
Q Inside circumferential
Outside circumferential
Inside and outside meridional

5. R E S U L T S

.05

.IO

-15

"20

-;iS

Fig. 10. Equivalent stress ratios. Radial nozzles.

Equivalent stress ratio at maximum axial positions
in nozzle.
Equivalent stress ratio at maximum hoop positions,
maximum stress in nozzle.
Equivalent stress ratio on outer surface of plate at
toe of weld

5.1. Radial nozzle s

R e c o r d e d s t r a i n r e a d i n g s f o r all gauges w e r e
p l o t t ed ag ai n st p r e s s u r e up to 240 p s i g to v e r i f y
l i n e a r i t y . Strain v a l u e s at this p r e s s u r e w e r e
p l o t t ed ag ai n st r e s p e c t i v e gauge p o s i t i o n s and,
f r o m t h e s e g r a p h s , s t r e s s e s c a l c u l a t e d and ex p r e s s e d as s t r e s s c o n c e n t r a t i o n f a c t o r s (SCF)
b a s e d on an e x p e r i m e n t a l s h e l l m e m b r a n e s t r e s s
of 11000 l b / i n , z. Due to the p h y s i c a l s i z e of the
s t r a i n gauges it was not p o s s i b l e to position the
gauge g r i d c e n t r e s c l o s e r than 0.15 in. to the
w e l d / s h e l l plate i n t e r s e c t i o n , i . e . , the f i l l e t weld
toe. Consequently the c u r v e s for s t r a i n d i s t r i b u tion along the plate w e r e extended to the weld toe
position. The ' e x t r a p o l a t e d ' v a l u e s w e r e u s e d to
c a l c u l a t e s t r e s s e s at t h e s e points.
The c a l c u l a t e d S C F ' s a r e shown p l o t t ed r e l a tive to p o s i t i o n s in f i g s. 5-7. Fig. 8 shows the
m a x i m u m hoop and c o r r e s p o n d i n g axial s t r e s s e s
and m a x i m u m ax i al and c o r r e s p o n d i n g hoop
s t r e s s e s i n s i d e the n o z z l e s , plotted as S C F ' s
ag ai n st the r a t i o of n o z z l e t h i c k n e s s to i n t e r n a l
d i a m e t e r , i . e . , t / d i. The c u r v e showing hoop
s t r e s s e s has b e e n extended on the a s s u m p t i o n of

E X P E R I M E N T A L ELASTIC STRESS ANALYSIS

79

KEY :G&IJGES.
HOOP/CIRC.
AXIAL / MERID.
[] 4 5

s,(;,~s.

x
+
O

~,
[]

INSIDE H O O P / C I R C
OUTSIDE H O O P ] C I I
INSIDE AX/AL~ME
OUTSIDE A X I A L I M |
I NSIDE MAX. PRINq
OUTSIDE MAX. PRIN
INSIDE M I N . PRII~
OUTSIDE M I N . PRIN

O
f

\
2

SC.F.

/J \
i

SECTION

O
S.C.F.

A-A

F i g . 11. S t r e s s d i s t r i b u t i o n s f o r o b l i q u e n o z z l e no. 4.

-I

80

E. P R O C T E R and R. F. F L I N D E R S

.KEY :GAUGES
HOOP/CIRC.
+ AXIAL / MERID.

oi

D 45

S,~.F'S,
INSIDE H O O P I C I R C .
x OUTSIDE HOOP~ClRC.
+ INSIDE AXlALIMERID.
O OUTSIDE A X I A L I MERID.
I NSIDE M A X . PRINCIPAL.
OUTSIDE MAX. PRINCIPAL.
~. INSIDE M I N . PRINCIPAL,
D OUTSIDE MIN. PRINCIPAL.

1k
i

/~ll,
2

-I
S. C.F.

21
0

i
I
SEC TION

A'A

0
S.C.F.

F i g . 12. S t r e s s d i s t r i b u t i o n s f o r o b l i q u e n o z z l e no. 5.

-I

E X P E R I M E N T A L ELASTIC STRESS ANALYSIS

81

KEY:-

~AUGt~S
HOOP / CIRC.
+ AXIAL /MERIDIONAL.
a 45

.s.c.F's.

INSIDE HOOP/CIRC.
x OUTSIDE HOOP/CIRC.
+ I NSIDE A X I A L / M E R I D I O N A L .
O OUTSI[)E A X I A L / M E R I O I O N A L .
INSIDE M A X . PRINCIPAL,
OUTSIDE MAX, PRINCIPAL,
h I N S I D E M t N . PRINCIPAL.
E10UTSIrp E MIN, PRINCIPAL.

I
$ . C . I~

I
S.C. E

U
!

0
S.C.F.

-I

SECTION 'AAI

Fig. 13. S t r e s s d i s t r i b u t i o n s f o r oblique nozzle no. 6.

-I

82

E. PROCTER and R. F. FLINDERS

AXlS'E'

3~:

2.~

I.S

X--AXIS~A * MAX. HOOP S.C,F.IS.

F'I--AXIS'B' MAX. HOOP S.C.F?S.
- - A X I S .~s AXIAL 5.C,F?S. AT MAX. HOOP STRESS POSITIONS.
(~--AXIS ~B* AXIAL S.C,F.~.AT MAX HOOP STRESS POSITIONS.
A --A X IS *C* PRINCIPAL S~'F,~S. HAVING MAX, EOUIVALENT STRESS
VALUE.

"O

IO ' ~ ' t :

.....
"25

"1

Fig. 15a. Maximum c i r c u m f e r e n t i a l and meridional

S C F ' s at toe of welds (oblique nozzles).
(aCA) c i r c u m f e r e n t i a l SCF at A outside vessel
(aCB) c i r c u m f e r e n t i a l SCF at B outside v e s s e l

I.O

" 2 L

(CrMA) m e r i d i o n a l SCF at A outside vessel

+ (OMB) m e r i d i o n a l SCF at B inside vessel

OS

~ "- -

--J'C
'OS

Fig. 14. S t r e s s concentration f a c t o r s inside oblique

nozzles.
x Axis A m a x i m u m hoop S C F ' s
[] Axis B m a x i m u m hoop S C F ' s
Axis A axial SCFTs at m a x i m u m hoop s t r e s s positions
@ Axis B. Axial 8 C F ' s at m a x i m u m hoop s t r e s s p o s i tions
~ Axis C. P r i n c i p a l SCFTs having m a x i m u m equivalent
s t r e s s value
s t r e s s r a t i o s of 2.0 f o r a p l a i n c y l i n d r i c a l o p e n i n g w i t h o u t r e i n f o r c e m e n t , i . e . , t/d i = 0 , a n d 1.0
for full compensation. Similar curves are shown
i n fig. 9 f o r m a x i m u m c i r c u m f e r e n t i a l a n d m e r idional SCF's inside and outside the shell plate.
These curves have also been extended assuming
the mean circumferential and meridional SCF's
to b e 2.0 a n d 0 r e s p e c t i v e l y , f o r a p l a i n c y l i n d r i c a l o p e n i n g w i t h o u t r e i n f o r c e m e n t , i . e . , t/d i =0.
Nozzle thicknesses have been calculated for the
t e s t c a s e a c c o r d i n g to B S 1 5 0 0 a n d B S 3 9 1 5 r e spectively. The thickness/diameter
ratio for
e a c h c a s e i s s h o w n on t h e p l o t s i n f i g s . 8 a n d 9
to i n d i c a t e c o m p a r a t i v e s t r e s s r a t i o s .
Since first yield does not necessarily occur at

" IO

"IS

"~O

.25

Fig. 15b. Maximum c i r c u m f e r e n t i a l and m e r i d i o n a l

S C F ' s at toe of welds (oblique nozzles).
y ((rCc) c i r c u m f e r e n t i a l SCF at C outside vessel
[] ((~CD) c i r c u m f e r e n t i a l SCF at D inside v e s s e l
). ((rMc) m e r i d i o n a l SCF at C outside vessel

((YMD) m e r i d i o n a l SCF at D inside v e s s e l

the maximum stress position, equivalent stress

ratios have been calculated, based on Von Mises
criterion and assuming the third principal stress
t o b e z e r o . T h e s e v a l u e s a r e s h o w n i n fig. 10.
5.2. Oblique nozzles
Strain values were plotted and SCF's calculated on the same basis as the radial nozzles. However, in this case gauge pairs and rosettes could
not be fixed at the same position. Therefore, in
calculating stresses, the strain distributions
w e r e i n t e r p o l a t e d i n o r d e r to o b t a i n t h e s t r a i n
components at the same location.
The calculated SCF's are shown plotted relat i v e t o p o s i t i o n i n f i g s . 1 1 - 1 3 . F i g . 14 s h o w s t h e

EXPERIMENTAL ELASTIC STRESS ANALYSIS

83

IO

INSIDE ~'VI~CI'OR ~ALE

,30

-20

S~:'1.O

Fig. 16. Maximum and minimum SCF's and directions at toe of welds. Oblique nozzles.
O ~PE maximum principal SCF's at : I inside vessel
[] ~PE minimum principal SCF's at
[] (~PF maximum principal SCF's at F t outside vessel
/h ~PF minimum principal SCF's at F

"~"q)

~ B

2
8

0 5

-lO

.I 5

.20

.2S

~;.
Fig. 17. Maxiraum SCF's in shell plate.
ObLique nozzles.
O'PE max.
ffCA y ff CC
ffC B
G ffMA

+ ffM B

~ECrCD see fig. 15

~k a M C
OO-MD

[] (rpE min. see fig. 16

[] (rpF max.
A O'pF rain.

.O5

-IO

-IS

.20

,2S

Fig. 18. Equivalent s t r e s s ratios for oblique nozzles.

X axis A see + position A
[] position E see
see [] position F fig.
G axis B fig. [] position B fig.
axis C 14
position C 15
16
position D

84

E. PROCTER and R. F. FLINDERS

m a x i m u m hoop and c o r r e s p o n d i n g axial S C F ' s

inside the n o z z l e s on axial p l a n e s through the
m a j o r axis of the i n t e r s e c t i o n e l l i p s e , plotted
a ga i n s t t / d i. In addition S C F ' s of m a x i m u m and
m i n i m u m p r i n c i p a l s t r e s s e s on the axis n o r m a l
to the above are shown, t h e s e l a t t e r v a l u e s being
l o c a t e d at the position of m a x i m u m e q u i v a l e n t
s t r e s s . In this c a s e the value f o r the thinnest
n o z z l e t e s t e d is not shown due to the f a i l u r e of a
gauge. F i g s . 15 and 16 show s i m i l a r c u r v e s for
the S C F ' s at the weld t o e s on the i n n e r and o u t e r
s u r f a c e s of the s h e l l plate. In fig. 16 the d i r e c tions of the p r i n c i p a l s t r e s s e s a r e also shown.
To i l l u s t r a t e m o r e c l e a r l y the position of the
absolute m a x i m u m the c u r v e s a r e shown plotted
t o g e t h e r in fig. 17.
The equivalent s t r e s s r a t i o s c a l c u l a t e d f r o m
the above v a l u e s for both n o z z l e s and s h e l l plate
a r e shown in fig. 18.
Nozzle t h i c k n e s s e s have again been c a l c u l a t e d
a c c o r d i n g to BS1500 and BS3915 and t h i c k n e s s
d i a m e t e r r a t i o s shown at the a p p r o p r i a t e v a l u e s
on the above c u r v e s , indicating c o m p a r a t i v e
s t r e s s r a t i o s . In o r d e r to include the value for
BS1500 it was n e c e s s a r y to e x t r a p o l a t e the c u r v e s .

6. DISCUSSION OF R E S U L T S

6.1. Radial n o z z l e s
The m a x i m u m s t r e s s e s o c c u r r i n g at the r a d i a l
n o z z l e s a r e on the o u t e r s u r f a c e of the s h e ll
plate, at the weld toe, in the c i r c u m f e r e n t i a l
d i r e c t i o n . F o r the n o z z l e t e s t e d , the S C F ' s r a n g e
f r o m 1.7 to 1.16 with i n c r e a s i n g n o z z l e t h i c k n e s s .
T h e r e is s o m e bending of the s h e l l plate, howe v e r , which i n c r e a s e s with the r e d u c t i o n in nozzle t h i c k n e s s (fig. 9). M a x i m u m hoop s t r e s s r a tios inside the n o z z l e s r a n g e f r o m 1.61 to 1.03,
i . e . , slightly l o w e r than those in the s h e l l plate
(fig. 8). The m e a n s t r e s s in the plate a p p r o x i m a t e s
to hoop s t r e s s in the n o z z l e at the s m a l l e r t h i c k nesses.
Fig. 5, i l l u s t r a t i n g in s o m e detail the d i s t r i bution of s t r e s s in the s h e l l p l a t e , shows that
the c i r c u m f e r e n t i a l s t r e s s i n c r e a s e s smoothly as
the weld toe is a p p r o a c h e d , while the m e r i d i o n a l
s t r e s s d e c r e a s e s until, at a d i s t a n c e a p p r o x i m ating to nozzle t h i c k n e s s f r o m the weld toe, a
s h a r p i n c r e a s e o c c u r s . Bending s t r e s s in the
m e r i d i o n a l d i r e c t i o n is e l i m i n a t e d at the weld toe.
The S C F ' s shown in figs. 5-7 i l l u s t r a t e that
the m a x i m u m s t r e s s inside each n o z z l e o c c u r s in
the hoop d i r e c t i o n and c o i n c i d e s with the s h e l l
t h i c k n e s s c e n t r e line. The s t r e s s e s die away
r a p i d l y , dependent upon n o z z l e t h i c k n e s s , each

side of the peak. The axial S C F ' s p r o d u c e c u r v e s

peaking at a n u m b e r of points with a m a x i m u m
value which is c o m p r e s s i v e and coincident with
the n o z z l e / w e l d i n t e r f a c e on the outside of the
shell. Whilst the magnitude of m a x i m u m axial
s t r e s s is dependent on both nozzle t h i c k n e s s and
weld p e n e t r a t i o n , i t s position is dependent on
p e n e t r a t i o n only; as the weld a p p r o a c h e s full
p e n e t r a t i o n the m a x i m u m axial s t r e s s will app r o a c h a position coincident with the c e n t r e line
of the plate and m a x i m u m hoop s t r e s s .
The design of n o z z l e s a c c o r d i n g to the two
p r e s s u r e v e s s e l codes w e r e b ased on actual t e s t
plate t h i c k n e s s and ambient t e m p e r a t u r e conditions. The c u r v e s in fig. 9 indicate that the m a x i m u m S C F ' s in the sh el l would be 1.1 for a nozzle d e s i g n e d to BS1500 and 1.86 if d e s i g n e d to
BS3915. Fig. 8 i n d i c a t e s that c o r r e s p o n d i n g
m a x i m u m S C F ' s in the n o z z l e s would be 1.0 and
1.75.
The m a x i m u m SCF v a l u e s for the BS3915 d esign a r e well within the a c c e p t a b l e l i m i t of 2.25
stated in Appendix A of the code. H o w e v e r , f i r s t
y i e l d does not o c c u r at the m a x i m u m s t r e s s position. Fig. 10 c l e a r l y i n d i c a t e s that, b ased on
Von M i s e s c r i t e r i o n , f i r s t y i e l d o c c u r s inside
the nozzle at the m a x i m u m axial s t r e s s position,
i . e . , coincident with the c e n t r e line of the weld
f i l l et .
F o r the BS3915 design the m a x i m u m e q u i v a lent s t r e s s r a t i o is shown, on e x t r a p o l a t i o n , to
be 2.35. Since, in this code, design m e m b r a n e
s t r e s s is b a s e d on 2 uniaxial y i e l d s t r e s s for the
m a t e r i a l the p r e s s u r e to f i r s t y i e l d will be ex c e e d e d 1.57 t i m e s at design p r e s s u r e and 1.96
t i m e s at p r o o f t e s t p r e s s u r e , a s s u m i n g this to
be 1.25 t i m e s the design value. At t e s t p r e s s u r e
the v o l u m e of n o z z l e m a t e r i a l s u b j e c t e d to p l a s t i c
conditions will be l i t t l e m o r e than that contained
within the sh el l p l at e t h i c k n e s s . P l a s t i c s t r e s s e s
in the s h e l l plate will be contained within a c i r c l e ,
i n s c r i b e d f r o m the nozzle c e n t r e of r a d i u s app r o x i m a t i n g to n o z z l e b o r e . The l i m i t i n g f a c t o r
on t h i c k n e s s of r a d i a l n o z z l e s d e s i g n e d to this
code may well be g o v e r n e d by welding t e c h n i q u e s .
F o r i n s t a n c e , at four t i m e s the s i z e of the t e s t
v e s s e l , which c o r r e s p o n d s with e x i s t i n g r e a c t o r
v e s s e l s , a r a d i a l n o z z l e would be of the o r d e r of
0.28 in. thick welded into ~t 4 in. thick sh el l plate.
In the c a s e of BS1500 b a s e d on a design s t r e s s
of U T S / 4 , design p r e s s u r e is of the o r d e r of 0.68
t i m e s p r e s s u r e to f i r s t y i e l d whilst t e s t p r e s s u r e , wMch is 1.5 t i m e s design value, a p p r o x i m a t e s to f i r s t yield.

EXPERIMENTAL ELASTIC STRESS ANALSYSIS

6.2. Oblique nozzles~
In the c a s e of the n o z z l e s mounted at 45
obliquity the m a x i m u m s t r e s s e s o c c u r inside the
n o z z l e s and not on the s h e l l plate, as in the c a s e
of r a d i a l n o z z l e s . T h e s e m a x i m u m s t r e s s e s a r e
in the hoop d i r e c t i o n at p o s i t i o n s coincident with
the c e n t r e of the we].d in the o u t e r obtuse angle.
The S C F ' s ran g e f r o m 2.91 to 2.1 with i n c r e a s i n g
n o z z l e t h i c k n e s s (fi~:. 14). Axial s t r e s s e s in the
n o z z l e s on this and the o th e r axes peak at a n u m b e r of p o s i t i o n s in s i m i l a r m a n n e r to the r a d i a l
c a s e s . The magnitude and position of t h e s e s t r e s s
peaks a r e obviously dependent on n o z z l e t h i c k n e s s
and depth of weld p e n e t r a t i o n .
M a x i m u m s t r e s s e s in the shell plate o c c u r , as
e xpe ct ed , at the weld toes. Fig. 17 i l l u s t r a t e s
that, for v a l u e s of l//di<O.17, t h e s e m a x i m a o c c ur inside the v e s s e l on an axial plane through
the m i n o r axis of the i n t e r s e c t i o n e l l i p s e . F r o m
fig. 16, which shows th e s e p r i n c i p a l s t r e s s r a t i o s
and t h e i r d i r e c t i o n s at t h e s e p o s i ti o n s only, it
can be s e e n that bending in the shell plate is app r e c i a b l e f o r the t h i n n e r n o z z l e s . Since the p r i n c ipa l s t r e s s d i r e c t i o n s change f r o m inside to outside the s h e l l plate, m e a n s t r e s s cannot be dir e c t l y d e t e r m i n e d . H o w e v e r , it is e a s i l y seen
that m e a n s t r e s s will be no g r e a t e r than the c i r c u m f e r e n t i a l s t r e s s e s at the m a j o r axis p o s i t i o n s .
F o r v a l u e s of t / d i > 0 . 1 7 , m a x i m u m S C F ' s o c c u r
in the m e r i d i o n a l d i r e c t i o n at the m a j o r axis posi t i o n s (fig. 17). Fig. 15 shows that the m a x i m u m
s t r e s s d i r e c t i o n s at t h e s e p o s i t i o n s change f r o m
m e r i d i o n a l to c i r c u m f e r e n t i a l for v a l u e s of t / d i <
0.17. Fig. 14 i n d i c a t e s that the absolute m a x i m u m
S C F ' s would be 2.0 f o r a nozzle d e s i g n e d to
BS1500 and 2.7 if d e s i g n e d to BS3915, which is
in e x c e s s of that c o n s i d e r e d as the l i m i t i n g value
in Appendix A of the code, i . e . , 2.25. M a x i m u m
s h e l l plate s t r e s s e s would be 1.4 and 1.89, r e s p e c t i v e l y , as shown in fig. 17.
E q u i v a l e n t s t r e s s r a t i o s inside the n o z z l e s and
on each side of the s h e l l plate, shown in fig. 18
i n d i c a t e s w h e r e f i r s t y i e l d will o c c u r in the v a r ious n o z z l e s . The fact that f i r s t y i e l d does not
n e c e s s a r i l y o c c u r at m a x i m u m s t r e s s p o s i ti o n s
was e n d o r s e d in the l a t e r p l a s t i c t e s t s . F o r a
n o z z l e d e s i g n e d to BS3915 the m a x i m u m e q u i v a lent s t r e s s r a t i o is shown to be a p p r o x i m a t e l y
2.4, thus design and p r o o f t e s t p r e s s u r e s will be
a p p r o x i m a t e l y 1.6 and 2.0 t i m e s the p r e s s u r e to
f i r s t yield, r e s p e c t i v e l y . T h e s e m a x i m u m e q u i v a l e n t s t r e s s e s a r e s i m i l a r to those f o r the r a dial n o z z l e , although in this c a s e the m a x i m u m
SCF is a p p r e c i a b l y l a r g e r . At t e s t p r e s s u r e the
v o l u m e of m a t e r i a l in the nozzle in e x c e s s of
y i e l d point will be th:~t contained within l i n e s

85

drawn, at a d i s t a n c e roughly equal to half the

shell plate t h i c k n e s s , f r o m each side of the sh el l
plate. P l a s t i c i t y in the sh el l plate will 'be contained within a d i s t a n c e a p p r o x i m a t i n g to n o z z l e
r a d i u s f r o m the toe of the weld.
In the c a s e of the BS 1500 design the m a x i m u m
equivalent s t r e s s r a t i o will be of the o r d e r of
2.15, thus design p r e s s u r e will be m a r g i n a l l y in
e x c e s s of f i r s t yield, while proof t e s t p r e s s u r e
will be 1.61 t i m e s that to cause f i r s t yield.
The design of obliquely mounted n o z z l e s is
usually b a s e d on the ' e q u i v a l e n t ' r a d i a l n o z z l e ,
i . e . , oblique nozzle t h i c k n e s s is that c a l c u l a t e d
for a r a d i a l nozzle having a d i a m e t e r equal to
that of the m a j o r axis of the e l l i p s e f o r m e d at
the i n t e r s e c t i o n of the nozzle and sh el l plate.
S t r e s s e s have been cal cu l at ed , by the O ' C o n n e l l
and Chubb [5] method, f o r the r a d i a l n o z z l e
equivalent of the BS3915 oblique design f o r the
t e s t v e s s e l . The m a x i m u m e q u i v a l e n t s t r e s s
r a t i o was shown to be a l m o s t i d e n t i c a l to the
e x p e r i m e n t a l l y obtained value for the oblique
case. This t h e r e f o r e supports the method of
design, by c o n s i d e r i n g the ' e q u i v a l e n t ' r a d i a l
case.

7. CONCLUSIONS
1. Although m a x i m u m s t r e s s e s at r a d i a l nozzle to shell i n t e r s e c t i o n s o c c u r in the s u r r o u n d i n g
sh el l plate, the m a x i m u m equivalent s t r e s s e s ,
b ased on Von M i s e s c r i t e r i o n for yield, o c c u r in
the n o z z l e s at p o si t i o n s coincident with the c e n t r e s
of the weld f i l l e t s . In the oblique n o z z l e to sh el l
i n t e r s e c t i o n s the position of max. s t r e s s and max.
equivalent s t r e s s coincide at t / d i > 0 . ] . This is
on the i n n er s u r f a c e of the nozzle opposite the
outer obtuse weld fillet. F o r thinner n o z z l e s ,
m a x i m u m equivalent s t r e s s o c c u r s on the inner
s u r f a c e of the n o z z l e coincident with the i n n er
obtuse weld f i l l et , although the peak s t r e s s p o s i tion r e m a i n s the s a m e . It has also been d e m o n s t r a t e d that d i f f e r e n t n o z z l e s having si g n i f i can t l y
d i f f er en t S C F ' s can have s i m i l a r m a x i m u m equiv a l e n t s t r e s s r a t i o s . F o r instance in the BS3915
d esi g n s the m a x i m u m equivalent s t r e s s r a t i o s
a r e a p p r o x i m a t e l y 2.4 for both r a d i a l and 45
n o z z l e s while the S C F ' s at the c o r r e s p o n d i n g
p o si t i o n s a r e 1.75 and 2.7 r e s p e c t i v e l y .
These factors provide practical demonstration
of the l i m i t a t i o n s of design methods a c c e p t i n g
p l a s t i c i t y but d e s i g n e d on e l a s t i c a n a l y s i s by
allowing s p e c i f i e d v a l u e s f o r m a x i m u m SCF.
2. F o r both r a d i a l and oblique n o z z l e s d esigned to BS3915 it has been shown that p r o o f

86

E. PROCTER and R. F. FLINDERS

t e s t p r e s s u r e i s of the o r d e r of twice f i r s t yield

p r e s s u r e , although the m a x i m u m S C F ' s a r e app r e c i a b l y different and in the oblique c a s e , the
l i m i t i n g design c o n s i d e r a t i o n is exceeded. Since
the volume of m a t e r i a l subject to p l a s t i c i t y is
c o m p a r a t i v e l y s m a l l , this is quite acceptable by
m o d e r n design s t a n d a r d s for v e s s e l s subjected to
n o r m a l power plant r e q u i r e m e n t s . However,
m o r e c o n s e r v a t i v e design may well be c o n s i d e r e d
n e c e s s a r y for components r e q u i r e d to have long
fatigue life. F u r t h e r , to o v e r c o m e d i s t o r t i o n a l
p r o b l e m s of welding such n o z z l e s into thick shell
plate it may be n e c e s s a r y to i n c r e a s e nozzle
t h i c k n e s s beyond the r e q u i r e m e n t s of BS3915.
3. In view of 1 and 2 above, it is suggested
that the design l i m i t for nozzles should be b a s e d
on a m a x i m u m allowable equivalent s t r e s s , which
o c c u r s inside the nozzle. The acceptable value
may be decided on c o n s i d e r a t i o n of the fatigue
life r e q u i r e m e n t s of the v e s s e l . F o r the avoidance of low cycle fatigue the m a x i m u m allowable
equivalent s t r e s s could be d e t e r m i n e d on the
b a s i s of f i r s t yield p r e s s u r e not exceeding 0.5 x
proof test p r e s s u r e .
Oblique nozzle design, b a s e d on the ' e q u i v a l e n t '
r a d i a l case, a p p e a r s s a t i s f a c t o r y provided it is
b a s e d on m a x i m u m equivalent s t r e s s .
4. At the shell plate s u r f a c e s s u r r o u n d i n g r a dial n o z z l e s , the m e r i d i o n a l s t r e s s e s , which are
n o r m a l l y c o n s i d e r e d to d e c r e a s e as the nozzle

wall is approached, have been shown to i n c r e a s e

n e a r the weld toe to a value approaching the c i r c u m f e r e n t i a l s t r e s s . This c o n f i r m s indications
obtained during r e a c t o r v e s s e l proof t e s t s ,
although it is not shown by s i m p l e thin shell
theories.
5. The m e a s u r e m e n t s of nozzle tilt c o n f i r m
existing i n f o r m a t i o n obtained f r o m e x p e r i m e n t a l
and r e a c t o r v e s s e l s . Although tilt is s m a l l at
design p r e s s u r e s , i.e., l e s s than 10 m i n u t e s of
a r c , its d i r e c t i o n cannot be p r e d i c t e d .

ACKNOWLEDGEMENT
This paper i s published by p e r m i s s i o n of the
C e n t r a l E l e c t r i c i t y G e n e r a t i n g Board.

REFERENCES
[1] A. Grindrod and E. Procter, CEGB Report RD/B/
M.424 (1965).
[2] A. Grindrod and R. P. Fearnley, CEGB Report RD/
B/M.428 (1965).
[3] K. G Mantle and E. Procter, The Engineer 209 (1960)
527.
[4] P. H. R. Lane, The Engineer 204 (1957) 812.
[5] J M. O'Connell and E.J. Chubb, CEGB Report RD/
B/R.585 (1966).