APPENDIX 5 — MANDATORY

DESIGN BASED ON FATIGUE ANALYSIS

ARTICLE 5-1

5-100 ANALYSIS FOR CYCLIC number of cycles. This stress amplitude is calculated
OPERATION on the assumption of elastic behavior and hence has
the dimensions of stress, but it does not represent a
The suitability of a vessel component for specified
real stress when the elastic range is exceeded. The
operating conditions involving cyclic application of
fatigue curves are obtained from uniaxial strain cycling
loads and thermal conditions shall be determined by
data in which the imposed strains have been multiplied
the methods described herein, except that the suitability
by the elastic modulus and a design margin has been
of high strength bolts shall be determined by the
provided, so as to make the calculated stress intensity
methods of 5-120 and the possibility of thermal stress
and amplitude and the allowable stress amplitude di-
ratchet shall be investigated in accordance with 5-130.
rectly comparable. As an exception to the use of strain
If the specified operation of the vessel meets all of the
controlled test data, Fig. 5-110.2.2 curves B and C are
conditions of AD-160, no analysis for cyclic operation is
based on load controlled fatigue data. The curves have
required and it may be assumed that the peak stress
been adjusted, where necessary, to include the maximum
limit discussed in 4-135 has been satisfied by compliance
effects of mean stress, which is the condition where
with the applicable requirements for materials, design,
the stress fluctuates about a mean value which is
fabrication, testing, and inspection of this Division. If
different from zero. As a consequence of this procedure,
the operation does not meet all the conditions of AD-
it is essential that the requirements of 4-135 and 4-
160, a fatigue analysis shall be made in accordance
137 be satisfied at all times, with transient stresses
with 5-110 or a fatigue test shall be made in accordance
included, and that the calculated value of the alternating
with 6-170.
stress intensity be proportional to the actual strain
amplitude. To evaluate the effect of alternating stresses
5-101 Allowable Amplitude of Alternating of varying amplitudes, a linear damage relation is
Stresses assumed in 5-110.3(e).
The conditions and procedures of AD-160 and 5-110
are based on a comparison of peak stresses with strain 5-102 Loadings to Be Considered
cycling fatigue data. The strain cycling fatigue data
are represented by the design fatigue strength curves The loadings to be considered shall include those
of Figs. 5-110.1, 5-110.2.1, 5-110.2.2, 5-110.2.3, 5- loads that are due to testing of the vessel when such
110.3, and 5-110.4.1 These curves show the allowable testing is in addition to that required by this Division.
amplitude Sa of the alternating stress component (one-
half of the alternating stress range) plotted against the
5-110 DESIGN FOR CYCLIC LOADING
1 The tests on which the design curves are based did not include
tests at temperatures in the creep range or in the presence of unusually 5-110.1 Determination of Vessel’s Ability to With-
corrosive environments, either of which might accelerate fatigue stand Cyclic Loading. If the specified operation of
failure. Therefore, these curves are not applicable at operating temper- the vessel does not meet the condition of AD-160, the
atures for which creep is a significant factor. In addition, the designer
shall evaluate separately any effects on fatigue life which might ability of the vessel to withstand the specified cyclic
result from an unusually corrosive environment. operation without fatigue failure shall be determined

395
5-110.1 1998 SECTION VIII — DIVISION 2
as provided hereinafter. The determination shall be
made on the basis of the stresses at a point of the
vessel and the allowable stress cycles shall be adequate
for the specified operation at every point. Only the
stresses due to the specified cycle of operation need
be considered; stresses produced by any load or thermal
condition which does not vary during the cycle need
not be considered, since they are mean stresses and
the maximum possible effect of mean stress is included
in the fatigue design curves.
5-110.2 Significance of Compliance With Require-
ments for Cyclic Loading. Compliance with these
requirements means only that the vessel is suitable
from the standpoint of possible fatigue failure; complete
suitability for the specified operation is also dependent
on meeting the general stress limits of 4-130 and any
applicable special stress limits of 5-130.
5-110.3 Cyclic Loading Design Procedure. Subpara-
graphs 5-110.3(a) and 5-110.3(b) apply to the determina-
tion of primary plus secondary stress intensity range
(see 4-134) and peak stress intensity range (see 4-135).
(a) When Principal Stress Direction Does Not
Change. For any case in which the directions of the
principal stresses at the point being considered do not
change during the cycle, the following steps shall be
followed to determine the alternating stress intensity.
(1) Principal Stresses. Consider the values of the
three principal stresses at the point versus time for the
complete stress cycle. These are designated as s1, s2,
and s3 for later identification.
(2) Stress Differences. Determine the stress differ-
ences
S12 p s1 − s2
S23 p s2 − s3
S31 p s3 − s1
versus time for the complete cycle. In what follows,
the symbol Sij is used to represent any one of three
stress differences.
(3) Stress Intensity Range. Determine the extremes
of the range through which each stress difference Sij
fluctuates, and find the absolute magnitude of this range
for each Sij. Call the largest absolute magnitude of
these values Srij.
(b) When Principal Stress Direction Changes. For
any case in which the directions of the principal stresses
at the point being considered do change during the
396
5-110.3
stress cycle, it is necessary to use the following more
general procedure.
(1) Consider the values of the six stress compo-
nents st , sl , sr , tlt , tlr , and trt versus time for the
complete stress cycle.
(2) Choose a point in time when the conditions
are one of the extremes for the cycle (either maximum
or minimum, algebraically) and identify the stress com-
ponents at this time by the subscript i. In most cases
it will be possible to choose at least one time during
the cycle when the conditions are known to be extreme.
In some cases it may be necessary to try different
points in time to find the one which results in the
largest value of alternating stress intensity.
(3) Subtract each of the six stress components sti ,
sli, etc., from the corresponding stress components st ,
sl, etc., at each point in time during the cycle and
call the resulting components s ′t , s ′l, etc.
(4) At each point in time during the cycle, calculate
the principal stresses s ′1, s ′2, and s ′3 derived from
the six stress components s ′t , s ′l, etc. Note that the
directions of the principal stresses may change during
the cycle, but each principal stress retains its identity
as it rotates.
(5) Determine the stress differences,
S″12 p s ′1 − s ′2
S″23 p s ′2 − s ′3
S″31 p s ′3 − s ′1
versus time for the complete cycle and find the largest
absolute magnitude of any stress difference at any time.
Call this value Srij.
(c) When evaluating the limits for the primary plus
secondary stress intensity range, Srij is compared to the
3Sm limit (see 4-134).
(d) The alternating stress intensity Salt is one half
the value of Srij.
(e) Design Fatigue Curves. Figures 5-110.1, 5-
110.2.1, 5-110.2.2, 5-110.3, and 5-110.4 contain applica-
ble design fatigue curves for some of the materials
permitted by this Division [see AM-100(c)]. When
more than one curve is presented for a given material,
the applicability of each is identified. Where curves
for various strength levels of a material are given,
linear interpolation may be used for intermediate
strength levels of these materials. As used herein, the
397
APPENDIX 5 — MANDATORY

FIG. 5-110.1 DESIGN FATIGUE CURVES FOR CARBON, LOW ALLOY, SERIES 4XX, HIGH ALLOY STEELS AND
HIGH TENSILE STEELS FOR TEMPERATURES NOT EXCEEDING 700°F
Fig. 5-110.1
5-110.3 1998 SECTION VIII — DIVISION 2 5-110.3

TABLE 5-110.1
TABULATED VALUES OF Sa , ksi, FROM FIGURES INDICATED

Number of Cycles1

Figure Curve 1E1 2E1 5E1 1E2 2E2 5E2 8.5E22

5-110.1 UTS 115–130 ksi 420 320 230 175 135 100 ...
5-110.1 UTS ≤ 80 ksi 580 410 275 205 155 105 ...
5-110.2.1 ... 708 512 345 261 201 148 ...
5-110.2.2 ... See Table 5-110.2
5-110.3 Sy p 18.0 ksi 260 190 125 95 73 52 ...
5-110.3 Sy p 30.0 ksi 260 190 125 95 73 52 ...
5-110.3 Sy p 45.0 ksi 260 190 125 95 73 52 46
5-110.4 ... 708 512 345 261 201 148 ...
5-120.1 MNS3 ≤ 2.7Sm 1150 760 450 320 225 143 ...
5-120.1 MNS3 p 3Sm 1150 760 450 300 205 122 ...
GENERAL NOTES:
(a) All notes in the referenced figures apply to these data.
(b) Interpolation between tabular values is permissible based upon data representation by straight lines on a log-log plot. Accordingly, for
Si > S > Sj ,
[log (Si /S)] / log (Si /Sj )

1 2
N Nj
p
Ni Ni

where
S, Si , Sj p values of Sa
N, Ni , Nj p corresponding number of cycles from design fatigue data
Example: From data in the table, use the interpolation formula above to find the number of cycles N for Sa p 53.5 ksi when UTS ≤ 80
ksi in Fig. 5-110.1.
[log (64/53.5)] / log (64/48)

1 2
N 5000
p
2000 2000

N p 3540 cycles

NOTES:
(1) Number of cycles indicated shall be read as follows: I EJ p I × 10J, e.g., 5E2 p 5 × 102 or 500.
(2) These data points are included to provide accurate representation of curves at branches or cusps.
(3) Maximum nominal stress.

strength level is the specified minimum room tempera-
ture value. The design fatigue curves are defined over
a cyclic range of 10 to 106 cycles, except that for nickel–
chromium–molybdenum–iron alloy, a cyclic range of
10 to 108 cycles is provided in Fig. 5-110.4 and that
for series 3XX high alloy steels, nickel–chromium–iron
alloy, nickel–iron–chromium alloy, and nickel–copper
alloy, the design fatigue curves are extended to 1011
cycles in Fig. 5-110.2.2. Criteria for the use of the
latter curves are given in Fig. 5-110.2.2 and are also
presented graphically by the flowchart given in Fig. 5-
110.2.3.
(f) Use of Design Fatigue Curve. Multiply Salt [as
determined in (a) or (b)] by the ratio of the modulus
of elasticity given on the design fatigue curve to the
value used in the analysis. Enter the applicable design
fatigue curve at this value on the ordinate axis and
find the corresponding number of cycles on the axis
of abscissas. If the operational cycle being considered
is the only one which produces significant fluctuating
stresses, this is the allowable number of cycles.
(g) Cumulative Damage. If there are two or more
types of stress cycle which produce significant stresses,
their cumulative effect shall be evaluated as given
below.
(1) Designate the specified number of times each
type of stress cycle of types 1, 2, 3, etc., will be
repeated during the life of the vessel as n1 , n2 , n3 ,
etc., respectively. In determining n1 , n2 , n3 , etc., consid-
eration shall be given to the superposition of cycles
of various origins which produce a total stress difference
range greater than the stress difference ranges of the
individual cycles. For example, if one type of stress
cycle produces 1000 cycles of a stress difference varia-

398
5-110.3 APPENDIX 5 — MANDATORY 5-112

TABLE 5-110.1
TABULATED VALUES OF Sa , ksi, FROM FIGURES INDICATED

Number of Cycles1

1E3 2E3 5E3 1E4 1.2E42 2E4 5E4 1E5 2E5 5E5 1E6 2E6 5E6 1E7 2E7 5E7 1E8

78 62 49 44 43 36 29 26 24 22 20 ... ... ... ... ... ...

83 64 48 38 ... 31 23 20 16.5 13.5 12.5 ... ... ... ... ... ...
119 97 76 64 ... 55.5 46.3 40.8 35.9 31.0 28.3 ... ... ... ... ... ...

44 36 28.5 24.5 ... 21 17 15 13.5 12.5 12.0 ... ... ... ... ... ...
44 36 28.5 24.5 ... 19.5 15 13 11.5 9.5 9.0 ... ... ... ... ... ...
39 24.5 15.5 12 ... 9.6 7.7 6.7 6.0 5.2 5.0 ... ... ... ... ... ...
119 97 76 64 ... 56 46.3 40.8 35.9 26.0 20.7 18.7 17.0 16.2 15.7 15.3 15.0
100 71 45 34 ... 27 22 19 17 15 13.5 ... ... ... ... ... ...
81 55 33 22.5 ... 15 10.5 8.4 7.1 6 5.3 ... ... ... ... ... ...

tion from zero to +60,000 psi and another type of U3 p n3 /N3

stress cycle produces 10,000 cycles of a stress difference
variation from zero to −50,000 psi, the two types of
etc.
cycle to be considered are defined by the following
(5) Calculate the cumulative usage factor U from
parameters:
Type 1 cycle:
U p U 1 + U2 + U3 + . . .
n1 p 1000
etc.
(6) The cumulative usage factor U shall not ex-
Salt 1 p (60,000 + 50,000) /2 p 55,000 psi
ceed 1.0.
Type 2 cycle:

5-111 Local Structural Discontinuities

n2 p 9000
Salt 2 p (50,000 + 0) /2 p 25,000 psi
(2) For each type of stress cycle, determine the
alternating stress intensity Salt by the procedures of (a)
or (b) above. Call these quantities Salt 1, Salt 2, Salt 3, etc.
(3) For each value Salt 1, Salt 2, Salt 3, etc., use
the applicable design fatigue curve to determine the
maximum number of repetitions which would be allow-
able if this type of cycle were the only one acting.
Call these values N1 , N2 , N3 , etc.
(4) For each type of stress cycle, calculate the
usage factors U1 , U2 , U3 , etc., from
These effects shall be evaluated for all conditions
using stress concentration factors determined from theo-
retical, experimental, or photoelastic studies or finite
element stress analysis techniques. Experimentally deter-
mined fatigue strength reduction factors may be used
when determined in accordance with the procedures of
6-180, in lieu of specific values when provided in this
Division and except for high strength alloy steel bolts
and studs for which the requirements of 5-110 shall
apply when using the design fatigue curve of Fig.
5-120.1. Except for the case of crack-like defects, no
fatigue strength reduction factor greater than five need
be used.

U1 p n1 /N1 5-112 Fillet Welds

Fillet welds shall not be used in vessels for joints
U2 p n2 /N2 of Categories A, B, C, or D (see Fig. AD-400.1),

399
 Fig. 5-110.2.1

400
1998 SECTION VIII — DIVISION 2

FIG. 5-110.2.1 DESIGN FATIGUE CURVE FOR SERIES 3XX HIGH ALLOY STEELS, NICKEL–CHROMIUM–IRON
ALLOY, NICKEL–IRON–CHROMIUM ALLOY, AND NICKEL–COPPER ALLOY FOR TEMPERATURES NOT
EXCEEDING 800°F AND Sa > 28.2 ksi (USE FIG. 5-110.2.2 FOR Sa ≤ 28.2 ksi)
 APPENDIX 5 — MANDATORY Fig. 5-110.2.2

FIG. 5-110.2.2 DESIGN FATIGUE CURVE FOR SERIES 3XX HIGH ALLOY STEELS, NICKEL–CHROMIUM–IRON
ALLOY, NICKEL–IRON–CHROMIUM ALLOY, AND NICKEL–COPPER ALLOY FOR TEMPERATURES
NOT EXCEEDING 800°F AND Sa ≤ 28.2 ksi (USE FIG. 5-110.2.1 FOR Sa > 28.2 ksi)

401
5-112 1998 SECTION VIII — DIVISION 2 5-120

FIG. 5-110.2.3 GRAPHICAL PRESENTATION OF CRITERIA FOR USE OF CURVES IN FIG. 5-110.2.2

except as permitted for joints of Category C for slip- or contraction of the vessel produced by internal or
on flanges (see AD-413 and AD-711.1) and for joints external pressure.
of Category D as permitted in Article D-6. Fillet welds
may be used for attachments to pressure vessels using
one-half the stress limits of 4-131 through 4-134 for
primary and secondary stresses. Evaluation for cyclic
5-120 FATIGUE ANALYSIS OF BOLTS
loading shall be made in accordance with Appendix 5
using a fatigue strength reduction factor of four and Unless the vessel on which they are installed meets
shall include consideration of temperature differences all the conditions of AD-160 and thus requires no fatigue
between the vessel and the attachment and expansion analysis, the suitability of bolts for cyclic operation shall

402
5-120 APPENDIX 5 — MANDATORY 5-130

TABLE 5-110.2 (4) fillet radii at the end of the shank shall be
TABULATED VALUES OF Sa, ksi, such that the ratio of fillet radius to shank diameter
FROM FIG. 5-110.2.2 is not less than 0.060;
(5) the fatigue strength reduction factor used in
Number of Cycles
[Note (1)] Curve A Curve B Curve C
the fatigue evaluation shall not be less than 4.0.

1E6 28.2 28.2 28.2

2E6 26.9 22.8 22.8 5-121 Acceptability for Cyclic Operation
5E6 25.7 19.8 18.4
1E7 25.1 18.5 16.4 The bolts shall be acceptable for the specified cyclic
2E7 24.7 17.7 15.2 application of loads and thermal stresses provided the
cumulative usage factor U, as determined in 5-110.3(e),
5E7 24.3 17.2 14.3
does not exceed 1.0.
1E8 24.1 17.0 14.1
1E9 23.9 16.8 13.9
1E10 23.8 16.6 13.7
1E11 23.7 16.5 13.6
5-122 Fatigue Strength Reduction Factor for
Threads
GENERAL NOTES:
(a) All Notes in Fig. 5-110.2.2 apply to these data. Unless it can be shown by analysis or test that a
(b) Interpolation between tabular values is permissible based upon lower value is appropriate, the fatigue strength reduction
data representation by straight lines on a log-log plot. See Table
5-110.1, General Note (b). factor used in the fatigue evaluation of threaded mem-
bers shall not be less than 4.0.
NOTE:
(1) The number of cycles indicated shall be read as follows: I EJ p
I × 10 J, e.g., 5E6 p 5 × 106 or 5,000,000.
5-130 THERMAL STRESS RATCHET IN
SHELL
It should be noted that under certain combinations
of steady state and cyclic loadings there is a possibility
be determined in accordance with the procedures which of large distortions developing as the result of ratchet
follow. action; that is, the deformation increases by a nearly
(a) Bolts made of materials which have minimum equal amount for each cycle. Examples of this phenome-
specified tensile strengths of less than 100,000 psi non are treated herein and in 5-140.
(689 MPa) shall be evaluated for cyclic operation by (a) The limiting value of the maximum cyclic thermal
the methods of 5-110, using the applicable design stress permitted in a shell loaded by steady state internal
fatigue curve, Figs. 5-110.1, 5-110.2.1, 5-110.2.2, 5- pressure in order to prevent cyclic growth in diameter
110.2.3, 5-110.3, and 5-110.4, and an appropriate stress is as follows. Let
concentration factor (see 5-122). y′pmaximum allowable thermal stress com-
(b) High strength alloy steel bolts and studs may be puted on an elastic basis, divided by the
evaluated for cyclic operation by the methods of 5- yield strength2 Sy
110 using the design fatigue curve of Fig. 5-120.1, xpmaximum general membrane stress due to
provided: pressure divided by the yield strength2 Sy
(1) the material is one of the following: SA-193 Case 1. Linear variation of temperature through the
Grade B7 or B16, SA-320 Grade L43, SA-540 Grades shell wall:
B23 and B24, heat treated in accordance with Section
5 of SA-540; 1
y′ p for 0 < x < 0.5
(2) the maximum value of the service stress at x
the periphery of the bolt cross section (resulting from
direct tension plus bending and neglecting stress concen-
y′ p 4(1 − x) for 0.5 < x < 1.0
trations) shall not exceed 2.7Sm, if the higher of the
two fatigue design curves given in Fig. 5-120.1 is used
Case 2. Parabolic constantly increasing or constantly de-
(the 2.0Sm limit for direct tension is unchanged);
creasing variation of temperature through the shell wall:
(3) threads shall be of a “V” type, having a
minimum thread root radius no smaller than 0.003 in.
(0.076 mm); 2 It is permissible to use 1.5Sm whenever it is greater than Sy.

403
5-130 1998 SECTION VIII — DIVISION 2 5-140

FIG. 5-110.3 DESIGN FATIGUE CURVE FOR WROUGHT 70 COPPER–30 NICKEL FOR
TEMPERATURES NOT EXCEEDING 700°F

y′ p 5.2(1 − x) for 0.615 < x < 1.0 5-140 PROGRESSIVE DISTORTION OF

and approximately for x < 0.615 as follows:
For x p 0.3 0.4 0.5
y′ p 4.65 3.55 2.70
(b) Use of the yield strength Sy in the above relations
instead of the proportional limit allows a small amount of
growth during each cycle until strain hardening raises the
proportional limit to Sy. If the yield strength of the material
is higher than is the endurance limit3 for the material, the
latter value shall be used, if there are to be a large number
of cycles, because strain softening may occur.
3 The endurance limit shall be taken as two times the Sa value at
106 cycles in the applicable fatigue curve of Fig. 5-110.1 or two
times the Sa value at 1011 cycles in the applicable fatigue curve of
Fig. 5-110.2.2.
NONINTEGRAL CONNECTIONS
Screwed-on caps, screwed-in plugs, shear ring closures,
and breech lock closures are examples of non-integral con-
nections which are subject to failure by bell-mouthing or
other types of progressive deformation. If any combination
of applied loads produces yielding, such joints are subject
to ratcheting because the mating members may become
loose at the end of each complete operating cycle and start
the next cycle in a new relationship with each other, with or
without manual manipulation. Additional distortion may
occur in each cycle so that interlocking parts, such as
threads, can eventually lose engagement. Therefore pri-
mary plus secondary stress intensities (4-134) which result
in slippage between the parts of a nonintegral connection in
which disengagement could occur as a result of progressive
distortion shall be limited to the allowable stress limits
given in 4-131 and 4-132.

404
405
APPENDIX 5 — MANDATORY

NOTES:
(1) E p 28.3 × 106 psi
(2) Table 5-110.1 contains tabulated values and a formula
for accurate interpolation of this curve.

FIG. 5-110.4 DESIGN FATIGUE CURVE FOR NICKEL–CHROMIUM–MOLYBDENUM–IRON,

ALLOYS X, G, C-4, AND C-276 FOR TEMPERATURES
NOT EXCEEDING 800°F
Fig. 5-110.4
 Fig. 5-120.1

406
1998 SECTION VIII — DIVISION 2

FIG. 5-120.1 DESIGN FATIGUE CURVE FOR HIGH STRENGTH STEEL BOLTING FOR TEMPERATURES
NOT EXCEEDING 700°F