COMPENS ATED AND UNCOMPENS ATED OPENINGS IN HEADS

DETERMINATION OF AREA TO BE COMPENSATED AND AREA AVAILABLE FOR

REINFORCEMENT
 COMPENS ATED AND UNCOMPENS ATED OPENINGS IN HEADS

DETERMINATION OF AREA TO BE COMPENSATED AND AREA AVAILABLE FOR REINFORCEMENT

Area to be compensated = basic area removed from the shell during opening = A
A = (dn,i + 2c)tr [in the figure on previous slide, dn,i = d]
where,
dn,i = inside diameter of nozzle = outside diameter of nozzle – 2 x nozzle wall thickness
c = corrosion allowance
tr = minimum shell wall thickness without corrosion allowance
Reinforcement area available from shell and nozzle = area of compensation = A’ =
As + An
where,
As = area available from shell for reinforcement = (dn,i + 2c)(ts - tr - c)
An = area available from nozzle for reinforcement = Ao + Ai
 COMPENS ATED AND UNCOMPENS ATED OPENINGS IN HEADS

DETERMINATION OF AREA TO BE COMPENSATED AND AREA AVAILABLE FOR REINFORCEMENT

where,
ts = actual shell wall thickness
Ao = area of the nozzle external to the vessel available for compensation

Ao = 2H1(tn - tr’ - c)
Ai = area of the nozzle inside the vessel (i.e. protruding nozzle) available for compensation
Ai = 2H2(tn - 2c)
NOTE:- For inside protrusion t r’ is zero, as there is no pressure difference ; but corrosion is from
both the sides
where,
tn = actual nozzle wall thickness
tr’ = minimum nozzle wall thickness without corrosion allowance
H1 = outside protrusion
H2 = inside protrusion
 COMPENS ATED AND UNCOMPENS ATED OPENINGS IN HEADS

DETERMINATION OF AREA TO BE COMPENSATED AND AREA AVAILABLE FOR REINFORCEMENT

If nozzle length outside the vessel is larger than the reinforcement boundary limit,
H1 =
If the nozzle length outside the vessel surface is less than or equal to the height of the
boundary limit,
H1 = actual length of the nozzle
If the inside protrusion of the nozzle goes beyond the reinforcement boundary limit,
H2 =
If inside protrusion is less or equal,
H2 = actual length of protruded portion

 If A > A’ or A > As + An
Area remained to be compensated = A - A’ or A - (As + An)
 DESIGN EXAMPLE
EXAMPLE - Examine the data given below to evaluate the requirement of compensation for the nozzle
opening in a cylindrical shell.
Outside diameter of the shell = 2 m
Maximum working pressure = 3.5 MN/m2
Wall thickness for the shell = 0.05 m
Corrosion allowance = 3x10-3 m
Weld joint efficiency factor = 1
Allowable stress (IS : 2002-1962-2A) = 96 MN/m2
Outside diameter of nozzle = 0.25 m
Nozzle-wall thickness = 0.016 m
Inside protrusion of nozzle — not desired
Length of nozzle above surface = 0.1 m
 SOLUTION – Area to be compensated = basic area removed from the shell during opening = A = (d n,i +
2c)tr
dn,i = dn,o - 2tn = 0.25 – 2 x 0.016 = 0.218 m
c = 3x10-3 m
 DESIGN EXAMPLE
tr =
where,
p = design pressure = 1.05x3.5 MN/m2 = 3.68 MN/m2
Do = outer diameter of the vessel = 2 m
f = allowable design stress for the material = 96 MN/m 2
J = weld joint efficiency factor = 1
Putting all these values in expression of tr,
tr = = = 0.0377 m
A = (dn,i + 2c)tr = (0.218 + 2 x 3x10-3) x 0.0377 = 8.443x10-3 m2
As = area available from shell for reinforcement = (d n,i + 2c)(ts - tr - c) = (0.218 + 2 x 3x10-3) x (0.05
– 0.0377 – 0.003)
As = area available from shell for reinforcement = 2.083x10-3 m2
An = area available from nozzle for reinforcement = A o (no inside protrusion)
An = Ao = 2H1(tn - tr’ - c)
 DESIGN EXAMPLE

where,
tn = Nozzle-wall thickness = 0.016 m
tr’ = = = 0.0047 m
H1 = = = 0.054 m
Actual length of nozzle above shell surface (0.1 m) is larger than 0.054 m
Hence,
An = Ao = 2H1(tn - tr’ - c) = 2 x 0.054 x (0.016 – 0.0047 – 0.003) =
0.8964x10-3 m2
Reinforcement area available from shell and nozzle = area of compensation
= A’ = As + An
Reinforcement area available from shell and nozzle = A’ = As + An = 2.083x10-3 +
0.8964x10-3 = 2.9794x10-3 m2
 DESIGN EXAMPLE
This difference is to be made up by ring pad, i.e.,
Area of ring pad = Ar ≥ 5.4636x10-3 m2
{2x(dn,i + 2c) - (dn,i + 2c + 2tr’)}tp ≥ 5.4636x10-3
Thickness of ring pad = tp ≥ 0.025 m
Ring pad dimensions:
Inner diameter = dn,o = 0.25 m
Outer diameter = 2 x (dn,i + 2c) = 0.448 m
Thickness = 0.025 m

NOTE:- if ring pad is used, H1 is measured from the surface of the ring pad. If actual length
of nozzle is more than H1 + tp, full value of H1 should be used for calculating An. Otherwise,
H1 should be substituted by actual nozzle length minus tp.
IN THIS EXAMPLE:- actual length of nozzle = 0.1 m > H1 + tp = (0.054 + 0.025) m = 0.079
 COMPENS ATED AND UNCOMPENS ATED OPENINGS IN HEADS

DETERMINATION OF AREA TO BE COMPENSATED AND AREA AVAILABLE FOR REINFORCEMENT

Ring pad compensated nozzle opening showing effective area for

compensation
 COMPENS ATED AND UNCOMPENS ATED OPENINGS IN HEADS

UNCOMPENSATED OPENINGS
 If A < A’ or A < As + A n
Openings can be left uncompensated
 It is not always necessary that any opening is to be externally reinforced. This is because, the wall
thickness of the vessels finally decided is larger than the theoretically required. This extra thickness
provides strength to the vessel walls to withstand stress concentration due to opening to some
extent.
 Parameters influencing the size of the opening diameter that can be left uncompensated:-
a) diameter of the vessel D o
b) thickness of the shell ts
c) pressure p and allowable stress value of the material
 As per IS: 2825 - 1969,
K' =
where, K’ is a factor based on the parameters influencing the size of the opening diameter that can be
left uncompensated
K' = 1 or a little over 1, an opening diameter up to 50 mm need not be compensated
K' < 1, larger opening diameter up to 200 mm can remain unreinforced
 DESIGN EXAMPLE
EXAMPLE - Examine the possibility of making one 0.05 m diameter uncompensated
opening in the shell of previous Design Example.
 SOLUTION – K' =
where,
p = design pressure = 1.05x3.5 MN/m2 = 3.68 MN/m2
Do = outer diameter of the vessel = 2 m
f = allowable design stress for the material = 96 MN/m2
ts = wall thickness for the shell = 0.05 m
c = corrosion allowance = 3x10-3 m
Putting all these values in expression of K',
K' = = = 0.8925 m
Since K' < 1.0, a 0.05 m diameter uncompensated opening can be made as per IS : 2825 -
1969