DESIGN OF NOZZLES

Uptill 2 nozzles
use type 1
3 nozzles or above
use type 2 or others except type 1
Always use blind with manhole
2 nozzles can be used with pad in cases where the design is failed
without pad.
Minimum width of pad must be 50 mm.
Do not use LWN flange until and unless it is said by client (e.g in case of
2 nozzles sometimes the nozzle design is failed by choosing type 1,
then choose type 2 and minimum width of wear plate or pad should be
50 mm but do not use LWN flange with 2 nozzle).
LWN flange is used with 2 nozzle or nozzles having more than 2 dia
only when client demands
While calculating the nozzle schedule use pipe schedule table
If nozzles are having 16 dia or less, then use pipe schedule table and
choose feasible pipe schedule according to nozzle dia requirements.
For 16 dia nozzles or lesser, choose Seamless pipe.
For more than 16 dia nozzles always make them with the same
thickness plate which is being used for vessel and such kind of nozzles
would be of welded pipe.
For more than 16 dia nozzles, choose Nozzle OD from Pipe schedule
table corresponding to the nozzle dia.
For more than 16 dia nozzles, While entering nozzle detail in compress,
if we choose ID then subtract twice the thickness (chosen thickness)
from nozzle OD (taken from Pipe schedule table) and then put this value
in compress.

Always remember that for 24 Man ways, choose the nozzle thickness as
12.7 (which is extra strong pipe schedule).
If it is required by client that use OD of nozzle as ID then take ID of
nozzle equal to OD and choose some nominal pipe thickness from pipe
schedule table.

DESIGN OF INSERT PLATES

Insert plates are used to increase area re-inforcement for nozzles to get
proper design.
There is no any advantage to increase pad width (for getting more area
re-inforcement in case of nozzle) more than the limit (mentioned by
compress by red dotted rectangle).
If such a case occurs when nozzle design is being failed prior to
approaching the maximum pad width limit then use insert plate.

The concept of insert plate is that a new plate of thickness more than
shell thickness is added at the area where a nozzle is present.

Calculation of Insert Plate Dia:

Method # 1

Limits of re-inforcement per UG-40 (message on compress

calculation page
for particular nozzle design)

D = 615.6 mm

(say)

= 650 mm (approx)

&
Dia of Insert Plate = 2 x d
= 2 x 650
= 1300 mm

Method # 2

Limits of Re-inforcement along the vessel wall

LR

440 mm (say)

Dia of Insert Plate = (2 LR) + (Nozzle dia)

= (2 x 440) + (1250)
= 2130 mm
= 2150 mm

(say)

NOZZLE LOADS

Different forces (stresses) and moments acting on nozzles due to

external loading
(Fluid flow) are given below

Pr

Radial force

Mc

Circumferential moment

Vc

Tangential force

ML

Longitudinal force

Mt

Torsional moment

Fr

Resultant Shear force

Mr

Resultant Moment

In order to add loads on nozzle while designing in compress, we proceed

in
different manner for heads and shells.

AT TOP/ BOTTOM HEADS:

Pr = -Fa
V2 = 0
V1 = Fc + FL

M1 = 0
Mt = Mt
M2 = Mc + ML

AT SHELL:
Values are taken directly from table according to given nozzle dia and
rating as.

FL = VL

Mc = Mc

Fa = Va

Mt = Mt

Fc = Vc

ML = ML

Note: If client has given nozzle loads in the form of any table or chart
then always use
Those values. If not given then demand from client. If still not
available then use

The standard table and take values as an approximation for

calculating nozzle
loads.

SELF-REINFORCED NOZZLES & FLANGES

In pressure summary during calculations of vessel on compress, MAWP

should not be minimum for nozzle reinforcement.
Minimum value of MAWP is only acceptable for shell or heads
If MAWP of a particular nozzle is more than shell or head but in nozzle
detail, there is warning that available re-inforcement governs the
MAWP of nozzle; then ignore this message as the nozzle is already
safe.
However if MAWP of a particular nozzle is minimum and in nozzle
detail, there is a warning that available re-inforcement governs the
MAWP of nozzle then either increase re-inforcement of the nozzle by
any of the following steps.
Increase barrel thickness
Put insert plate
Increase the shell thickness (if coarse length is not to long

If MAWP of a particular nozzle is more than shell or head but in nozzle

detail, there is warning that local stresses at the nozzle OD governs the
MAWP of nozzle; then ignore this message as the nozzle is already
safe.
However if MAWP of a particular nozzle is minimum and in nozzle
detail, there is a warning that local stresses at the nozzle OD governs
the MAWP of nozzle; then change Nominal Thickness of the nozzle.
If more than two self re-inforced nozzles are present on shell and their
design is failed despite of increasing barrel thickness up till maximum
level then rather than to use insert plate, use a proper length of shell
coarse like 2000 mm or max of 2500 mm and increase its thickness up
till the value where nozzle safe design is achieved.
In case of single self re-inforced nozzle which is being failed despite of
putting heavy barrel thickness, insert plate can be used and is more
feasible.
For ARAMCO always use series A flanges unless stated otherwise.

If during flange calculation, the size of flange is falling within the

standard limitations then always click on standard flange (B 14.7) in
Appendix 2.0 flange option.
If a BOOT is attached with the vessel and it is required by the client
that attach a flange with the boot, then it is made in two portions.
(a)

The upper side of flange and portion of the boot attached

with vessel are designed with the vessel. The portion of the
boot is considered as a nozzle and designed while going in
nozzle option

(b) Whereas the lower portion of the boot, the lower side of flange
and boot head (and any nozzle attached with this portion) are
designed in separate file with the same design conditions as of
vessel.
The boot is considered as shell and attach Appendix 2.0 flange
with standard specifications (if dia is not larger e.g. 40 and
available in the list of standard B14.7 flange option in Appendix
2.0 flange.

Add liquid level in this separate portion of the BOOT having

value equal to I.D of vessel + Total length of boot.

If boot head is provided with nozzle then add nozzles loads to the upper
part of boot by adding the nozzle effect.
WRC-297 can be done on compress as well.

Action -----perform FEA calculations-------Options

If in PV-ELITE during analysis on WRC-297, the following warnings come

then ignore them
The ratio Dn / Tn 20
Check the limitation of WRC bulletin 297

Dn / Dv 0.5
Check the limitation of WRC bulletin 297

Dn / Tv 5
Check the limitation of WRC bulletin 297

WRC-297 can be done for self re-inforced nozzles in the similar manner
as done for normal nozzles. Just insert the thickness of nozzle nominal
thickness (tn) rather than to insert heavy barrel thickness.
LWN is also a type of self re-inforced nozzle so if client demand self reinforced nozzles with lips then we make the sketch of LWN with lip as
well.

SKETCHING SELF RE-INFORCED CONTOUR NOZZLES

In order to make sketches of self-reinforced nozzles we proceed as

follows.
The standard sketch of lip nozzle is attached. There are different
dimensions being
Mentioned on it like A, B, C, D, H, H1, L & R.

A, B, C, & H can be directly obtained from the calculations of

particular nozzle from compress. R is the shell radius (single curvature)
in case if the nozzle is attached with the shell and 0.9 D or 0.17 D if the
nozzle is attached with the head. D, H1 & L can be calculated as
follows.

Calculation of D

Length of lip = R + 10 + (tan 30 x shell Th.)

Take minimum value of R as 19 mm. however R is variable depending

upon the weld Size as can be seen from ASME Sec VIII DIV 1.0. It should
be selected such that it is tangent to the fillet weld.

EXAMPLE:

Take R = 25 mm (approx.)
&

Tan 30 x Shell Th. = Shell Th. (approx.)

If Shell thickness is 20 mm & C = 856.6 mm, then

Length of lip = 25 + 10 + 20
= 55 mm

So
D = C + (2 x length of lip)
= 856.6 + (2 x 55)
= 958.6 mm

Calculation of H1

H1 = H + X + Z

Where
H = Height of barrel

(Normally taken as not more than 50mm during calculations in

compress)

Z = Length of nozzle starting from the end of taper of barrel

to final
Spray point of nozzle

(Normally from cost reduction point of view, Z is taken to be 50

mm in this
way the forging dye will be less expensive and the rest of the
length of the
nozzle is fabricated separately and is welded to the forged
nozzle whether
seamless or welded from plate)

X = Y x Tan 45
Y = Barrel Thickness Nominal Thickness of nozzle

EXAMPLE:

Let

Barrel Thickness = 60 mm
Nominal Th.

= 12.7 mm

Height of barrel = 50 mm

Then
X = (60 tan 45 12.7)
= (60-12.7) = 47.3 mm
So
H1 = H + X + Z
= 50 + 47.3 + 50 = 147.3 mm

Calculation of L

L = H1 + Shell Thickness
= 147.3 + 20 = 167.3 mm

Note: Always take R as shell radius for nozzles attached with shell
and write down single curvature in remarks.
In case of the nozzles attached to head, R is taken according
to the formula given below and write down double curvature in
remarks. As shown in the figure below.

For Radial Nozzle:

R = 0.9 D
For Hillside nozzles at knuckle of head:

R = 0.17D

Where D is the inner Dia of vessel.

Further note that this rule is for Ellipsoidal head only

INTERPRETATION FROM ARAMCO FOR

SELF RE-INFORCED NOZZLES

These nozzles do not require any external re-inforcement in order

to make them strong enough to withstand stresses and moments. In
other words we can say that these are the nozzles that do not require
any pad e.g long welded neck and contour nozzles (type 9).

1. Contour nozzles may be designed with lips or without lips according to

the requirements by ARAMCO standards.
2. In ARAMCO either JERMS or SAMSS standards, under following
conditions, contour nozzles with lips or without lips are required.

Cyclic condition
Equipment in thermal choc
(NO CONTOUR REQUIRED)

Thick wall vessel with thickness 50 mm & greater

Low alloy steel vessel with thickness 25 mm or greater
(SUBJECTED TO QUERY REPLY)

Nozzles opening of 900 mm with design temperature of > 400 C

(NO CONTOUR REQUIRED)

Vessel with design Temperature > 370 C

(NO CONTOUR REQUIRED)

Vessel with design Temperature < -45 C

(NO CONTOUR REQUIRED)

Lethal service

Vessel with design pressure > 0.7 MPa (70 bar)

Flange rating 600 # or greater except for CS material in non-cyclic
condition
For CS vessel with flange rating 900 # or greater
Hydrogen service
Severe wet H2S

Different sketches for self re-inforced nozzles (contour or LWN), with

or without lips has been shown above.

INSULATION

Insulation must be added with vessel according to client requirements. If no

any information is provided by the client in data sheet or material requisition
then use the following parameters for insulation.

NORMAL CASES:

Thickness = 38 mm ;

= 150 kg / m ;

Spacing = 200 mm

= 250 kg / m ;

Spacing = 100 mm

Weight = 150 kg

SEVERE CASES:

Thickness = 40mm ;

Weight = 150 kg

ADDITION OF BEDS

If mesh is of stainless steel then its approximately density is calculated

as follows (As a thumb rule)
As

s.s = 7880 kg / m
So
(mesh) s.s = 7880 / 3 = 2600 kg / m

Note:

Liquid holdup = 30 % (Approx.)

In case of beds addition in Compress, always mark only on

Present when
vessel is empty & include in lift weight

Important: We can also add bed in terms of vertical load. If the vessel is
having three
beds (N beds) then we have to add vertical load (w kg given).
For this
Purpose divide the vertical load w by N then add this load at
the mid of
each bed.

For packed beds always assume density equal to 2000 kg / m3 (i.e two
times of water). This is considered only when density is not given by
client.

EXAMPLE:

No of beds = 3
Total vertical load = 2000 kg

Then
Load / each bed = 2000 / 3
= 666.7 kg = 700 kg (Approx.)

Mark only Present when vessel is empty & include in lift

weight)

CALCULATIONS OF BED
ON COMPRESS

Bottom of bed
Bed depth

5050 mm
6000 mm

Bed Diameter

1900 mm

Bed Density

901 kg / m3

Liquid Hold up

20%

(Variable)
(Variable)
(Variable)
(Variable)

(Fixed) if not given in data sheet

Present when vessel is empty

Include in lift weight

STIFFENING RINGS

Stiffening rings are added only when vessel wall thickness governs at
external pressure

WIND & SEISMIC

FOR WIND:

SABIC always demands natural frequency for both wind and seismic as
1.00 or greater. So if H/D ratio of a column is more than 15 then always
choose natural frequency as 1.00 for SABIC related jobs.
ASCE 7.05 is selected if not given by client
Normally take basic wind speed as 155 km / hr (40 m / s)
Importance factor is taken as I = 1.15
Exposure = C
Wind direction factor (Kd) = 0.95
see table 6.4 (page-80)
Topographic factor (Kzt) = 1
Un-mark / de-select No wind shear below support in compress
Mark / select limit top deflection to 5mm for tall vessels having H/D
ratio more than 15.

Note: Normally client mentions the wind code to be followed and its other
specifications.
If no any information is given then assume the above values and also
see SAESA-112 (ARAMCO standard for wind & seismic) and select values
according to the
area where vessel is required to be installed.

FOR SEISMIC:

If no any code is given then choose UBC 1997 (building mounted)

Mark / select the following points while designing on compress
Consider vertical acceleration force multiplier = 0.3333
Min. weight multiplier = 0.2

UBC- seismic code inputs

Zone = 1
Importance factor

1.25

Soil Profile

SD

Rp factor (table 16-0)

H x / hr (eqn. 32.2)

Amplification factor ap

Take seismic data of Berri equivalent to Jubail (SAES-A-112)

Note: It is recommended that always use standards for wind & Seismic
according to the
Client and area where vessel is required to be installed and try
to avoid the use of
approximate values.

PLAT FORMS & LADDERS

Thumb rule to put plate forms is to install them after every 6m height.
Normally while designing platforms & ladders use the following scheme.

PLATE FORM # 1

Platform start angle

Platform end angle =

360

Ladder angle
situation)
Platform width

=
=

Platform to datum =
ahead)
Shell clearance

0
(worst case and can be changed)
0

(Depends upon the

1200 mm

(Normally fixed)

0.00 mm

(Variable for 2nd platform &

152.4 mm

Grating Weight

Railing weight

150 kg / m (Worst case fix)

=

491 N / m

(50 kg / m)

(Worst case

Ladder start to datum

ahead)

-4200 mm

(Variable for 2nd platform &

Ladder weight

981 N / m

(100 kg / m) (Worst case

fix)

fix)

Mark / check calculate & apply wind load

Wind force co-efficient (Cf)
=2
Railing height
= 1066.8 m
Mark / check present when vessel is empty
Mark / check Include in lift weight

PLATE FORM # 2

Platform start angle

Platform end angle =

360

Ladder angle
situation)
Platform width

0
(worst case and can be changed)
90

(Depends upon the

1200 mm

(Normally fixed)

Platform to datum =
ahead)

6600 mm

(Variable for 2nd platform &

Shell clearance

152.4 mm

Grating Weight

150 kg / m (Worst case fix)

Railing weight

491 N / m

(50 kg / m)

(Worst case

Ladder start to datum

ahead)

100 mm

(Variable for 2nd platform &

Ladder weight

981 N / m

(100 kg / m) (Worst case

fix)

fix)

Mark / check calculate & apply wind load

Wind force co-efficient (Cf)
=2
Railing height
= 1066.8 m
Mark / check present when vessel is empty
Mark / check Include in lift weight

TOP PLATE FORM

Platform length (l) =

2000 mm

(depends upon Dia of vessel)

Platform width (w) =

2000 mm

(depends upon Dia of vessel)

Platform angle
situation)
Offset

=
=

Platform to datum =
height)
Grating Weight

Railing weight

90

(Depends upon the

1000 mm

(Variable)

13400 mm

(Variable according to vessel

150 kg / m (Worst case fix)

=

491 N / m

(50 kg / m)

(Worst case

Ladder start to datum

vessel height)

6700 mm

(Variable according to

Ladder weight

981 N / m

(100 kg / m) (Worst case

fix)

fix)

Mark / check calculate & apply wind load

Wind force co-efficient (Cf)
=2
Railing height
= 1066.8 m
Mark / check present when vessel is empty
Mark / check Include in lift weight

DESIGN OF BOOTS

The distance mentioned from tangent of boot must be added in the half
of the dia of pressure vessel (in case of horizontal vessels) in order to
determine the projection length of boot while designing a vessel on
compress. As shown in the figure below.

DESIGN OF FLANGES

It must be noted that flange inside dia and pipe (nozzle) outside dia
must be same. Since flanges are available in standard sizes and pipes ID
can be made according to the flange ID requirements. As shown in the
figure below.

GENERAL NOTES ABOUT DATA SHEET

Data sheet always supersedes specifications

If some contradiction occurs between data sheet & code then consult
with client.

If no external design conditions are given then assume the following.

0 kpa @ 60C

If there is a requirement of full R.T (for ARAMCO) then whatever the

thickness comes, there would be requirement of self re-inforced
nozzles.
It means if shell thickness is 13mm at spot RT but clients
requirement is full R.T due to service. Then say by checking full
RT on compress, the thickness comes as 10 mm, then although the
thickness is very small but due to Full RT according to ARAMCO
standards, the designer would be intended to use self reinforced
nozzles.

CALCULATIONS ON PV-ELITE

While adding saddles to horizontal vessel, dont forget to change

dimension A (which is calculated from nearest tangent line) known
as distance of saddle from node.
In order to design a vessel on ASME Sec VIII Div 2.0, first change the
code from Div 1.0 to Div 2.0 then go to configuration and uncheck
ASME 2004, Ad-06. We will automatically move towards Div 2.0 Ed2007, A-08.
We cannot add more than four saddles with horizontal vessel in PVELITE.
If vessel is very long say (80m or 100m), then divide the vessel into
equal parts and determine saddle design and suggest number of
saddles for each part of vessel separately.
Always remember that whenever the material allowable stress is
required to be enter in PV-ELITE, then put allowable stress value
according to the design temperature of the part following SEC II part
D.
Whenever the allowable stress value of a non-pressure part is
required to be enter in the software then always calculate it by the
following formula
Allowable stress value
Fro non-pressure part

2/3 x (yield strength of material)

Number of nodes to be selected are always described as mentioned

below
Head # 1

10 to 20

Cylinder

20 to 30

Head # 2

30 to 40

If there are more than one cylinders then nodes are selected
accordingly. For example lets suppose there are three cylinders
then the order of selecting the nodes would be

Head # 1

10 to 20

Cylinder # 1 20 to 30
Cylinder # 2 30 to 40
Cylinder # 3 40 to 50
Head # 2

50 to 60

Orientation of vessel is selected by the following command.

Tools -----> Flip model orientation

Units are selected by the following command

Tools -----> Change Units

Code is selected from the option code given at the top of the pvelite environment.
Before starting 3D modeling on PV-Elite, always put the designed
parameters in Design Constraints tab as a default settings then
start modeling.
Fundamental concept of PV-Elite fro modeling a vessel is that in PVElite, firstly we have to put value of thickness (assumed) by our
perception. Then after running the software for code calculations, we

have to further decide that whether the thickness is required to be

reduced or increased or to be unchanged.
Similarly if there is a requirement of stiffener ring then always put
stiffener ring first and then calculate the required thickness.
For selection of thickness, always remember the following rule.
For head -----thickness

Finished thickness is not equal to nominal

(Nominal Th. = 1.15 x Finished Th.)

For Shell ------

Finished thickness is equal to nominal thickness

In order to regain the following tabs in PV-Elite environment, then go

to input and check all the required tabs.
General Input, heading, design Constraints, load calculations, wind
data & Seismic data.

For hemi spherical head there is no straight flange length.

For ellipsoidal head, check/select the straight flange length as 50
mm.
Always remember that while modeling a vessel with hemi-head in PVElite or compress, increase the length of the cylinder to about 100
mm than actual length of shell for welding provision.
For stiffener rings, the following rule is followed
Ring fillet weld leg size = 0.707 x Thickness of ring section attached
to vessel

For Aramco jobs, toe to toe distance between every pressure part
should be atleast 20mm e.g stiffener ring wear plate and saddle
etc.
For applying Nozzle loads on WRC-297, use the following link
Input---------->

Component analysis data

PV-ELITE WARNINGS

Warning # 1

Unity check on rib exceeds 1.0

Remedy
Increase number of ribs, rib thickness or web thickness.

Warning # 2
One or more saddle stress exceeds its allowable
Remedy
Increase number of saddles.