A comparison of stress analysis and limit analysis approaches for single and multiple nozzle combinations in cylindrical pressure vessels

The finite element method is the most commonly used approach when solving complex practical cylinder-cylinder junctions in pressure vessels. This is used when the geometrical arrangement is out with the permitted scope of the design-by-rule approaches or when detailed stress information is required as in a fatigue assessment. High-stress concentrations occur on the crotch corner for cylinder-cylinder joints, and it is possible to reach solutions for this problem by using both theoretical and numerical solutions. However, those approaches do not fully overlap nor have the same underlying assumptions. As such, an innovative high-fidelity finite element model has been developed to provide a holistic unified approach which can tackle a wide range of problems. In this study, various detailed nozzle design challenges were investigated including single and multiple nozzle combinations, nozzle-cylinder systems with different size ratios, fillet weld applications, limit loads and external loading cases were analyzed. The results obtained are compared with well-respected calculation methods such as WRC537, and a new approach is presented for the analysis of cylinder-cylinder combinations