Document No

L&T Engineering , Faridabad Rev 0A

PD-DP-0005

GUIDELINES FOR FLANGE Page2 of 48

LEAKAGE CALCULATION

TABLE OF CONTENTS

1 SCOPE ........................................................................................................................ 3
2 CODES / STANDARDS............................................................................................... 3
3 WORK PROCEDURE FOR CAESAR ......................................................................... 3
4 WORK PROCEDURE FOR AUTOPIPE. ................................................................... 18
5 REFERENCE DOCUMENTS .................................................................................... 48

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 Document No
L&T Engineering , Faridabad Rev 0A
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GUIDELINES FOR FLANGE Page3 of 48

LEAKAGE CALCULATION
1 SCOPE
This document states the guidelines to perform flange leakage calculation on CAESAR II
and Auto Pipe V8i.

2 CODES / STANDARDS

ANSI B16.5 Pipe flanges and flanged fittings.

ASME B16.47 Large diameter steel flanges.

ASME Sec. VIII Div.1&2 Rules for construction of pressure vessels.

ASME B 16.20 Metallic gaskets for pipe flanges.

ASME Sec. II, Part D Properties of materials.

ASME B31.3 Process piping.

3 WORK PROCEDURE FOR CAESAR

The procedure for calculation shall be explained through a sample calculation.

Flange size : 10

Flange Rating : 900#

Gasket type : RTJ-octagonal, B16.20 Cl.900 (as per PMS)

Material : Soft iron (as per PMS)

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L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page4 of 48

LEAKAGE CALCULATION

The input in CAESAR shall be as per following steps:

3.1 Select Analysis > flanges, to open the New job name specification dialog box shown
below:

File name shall be entered in Enter the name for the new job file field. (File name shall
be FlangeN where N is the flange node no. The flange with maximum load shall be
selected).

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Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page3 of 48

LEAKAGE CALCULATION
1 SCOPE
This document states the guidelines to perform flange leakage calculation on CAESAR II
and Auto Pipe V8i.

2 CODES / STANDARDS

ANSI B16.5 Pipe flanges and flanged fittings.

ASME B16.47 Large diameter steel flanges.

ASME Sec. VIII Div.1&2 Rules for construction of pressure vessels.

ASME B 16.20 Metallic gaskets for pipe flanges.

ASME Sec. II, Part D Properties of materials.

ASME B31.3 Process piping.

3 WORK PROCEDURE FOR CAESAR

The procedure for calculation shall be explained through a sample calculation.

Flange size : 10

Flange Rating : 900#

Gasket type : RTJ-octagonal, B16.20 Cl.900 (as per PMS)

Material : Soft iron (as per PMS)

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GUIDELINES FOR FLANGE Page6 of 48

LEAKAGE CALCULATION
e. Flange inside diameter [B] : Col.12 (B) i.e. matching ID of pipe welded
as per note given in ASME B16.5 table 18.

f. Flange thickness [tf] : Col.3 (tf).

g. Flange face OD or Lapjt cnt OD : Refer table 5 (Dont use this Value for lap joint)

h. Flange face ID or Lapjt cnt ID : Col.12 (B).

i. Small end hub thickness [g0] : (Col.5 col.12) /2 = (Ah-B) /2.

j. Large end hub thickness [g1] : (Col.4 col.12) /2 = (X-B) /2.

k. Hub length [h] : Col.8 (for weld neck) col.3 =Y- tf.

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GUIDELINES FOR FLANGE Page7 of 48

LEAKAGE CALCULATION
3.3 Bolts & Gaskets

Refer table as per class from ANSI B16.5, Table 17 for Bolt information.

a. Bolt circle diameter : Col.3. (w)

b. No. of bolts : Col.5.

c. Bolt diameter : Col.6.

d. Bolt initial tightening stress : Omitted (Default value shall be taken as

45000/d^ Psi), where d = Bolt diameter in inch.

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GUIDELINES FOR FLANGE Page5 of 48

LEAKAGE CALCULATION
In Enter the data directory field select the directory from the database dropdown and
press ok. This will trigger dialogs for flange leakage calculation.

3.2 Flange

Refer table as per class from ANSI B16.5, Table 18 to get dimensional data

a. Select flange type : As per PMS

b. Enter flange class : As per PMS

c. Flange grade : Col. 1 of table -1A from B16.5 for the

corresponding flange material.

d. Flange outside diameter [A] : Col.2 (O)

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GUIDELINES FOR FLANGE Page9 of 48

LEAKAGE CALCULATION
3.4 Material Data:

a) Flange material : Select from data base dropdown.

shall be as per PMS.

b) Bolt material : Select from database dropdown.

shall be as per PMS.

c) Design temperature : As per line list.

d) Flange allowable @ design temperature : Considered by CAESAR automatically

as per ASME Sec VIII Div 1.

e) Flange allowable @ ambient temperature : Considered by CAESAR automatically

as per ASME Sec VIII Div 1.

f) Flange modulus of elasticity @ design : Refer table C-6 of B31.3 for flange
material and temperature.

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GUIDELINES FOR FLANGE Page7 of 48

LEAKAGE CALCULATION
3.3 Bolts & Gaskets

Refer table as per class from ANSI B16.5, Table 17 for Bolt information.

a. Bolt circle diameter : Col.3. (w)

b. No. of bolts : Col.5.

c. Bolt diameter : Col.6.

d. Bolt initial tightening stress : Omitted (Default value shall be taken as

45000/d^ Psi), where d = Bolt diameter in inch.

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GUIDELINES FOR FLANGE Page8 of 48

LEAKAGE CALCULATION
Refer table 3, ASME B 16.20 / PMS for gasket dimensions.

e. Gasket outer dia. : According to Class/Rating/Ring No.(as per

ASME B 16.20, Table 3/4) i.e. (P+A).

f. Gasket inner dia. : According to Class/Rating/Ring No.(as per

ASME B16.20, table 3/4) i.e. (P - A).

g. Uncompressed gasket thickness : According to Class/Rating/Ring No.(as per

ASME B16.20, table 3/4) i.e. H.

h. Effective gasket modulus : Elastic Modulus at ambient temperature.

(Refer Sec II part D, Table TM-1).

i. Leak pressure ratio [m] : Refer table 2-5.1 of mandatory appendix 2 from
ASME section VIII, Division I.

u. Gasket seating stress [y] : Refer table 2-5.1 of mandatory appendix 2 from
ASME section VIII, Division I.

v Nubbin width (or ring joint width) : Width of ring for RTJ gasket.

X Facing sketch : Refer table 2-5.1 &2-5.2 of mandatory appendix 2

from ASME Section VIII, Division I. use Coade
equivalent no.

y Facing column : Refer table 2-5.1 &2-5.2 of mandatory appendix 2

from ASME Section VIII, Division I. use Coade
equivalent no.

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GUIDELINES FOR FLANGE Page12 of 48

LEAKAGE CALCULATION
3.10 Caesar output report:

Pass report sample:

FLANGE LEAKAGE/STRESS CALCULATIONS

Flange Inside Diameter [B] (User to verify) ......(mm ) 247.630
Flange Thickness [t]..............................(mm.) 69.900
Flange Rating (Optional) .............................. 900.000

Bolt Circle Diameter .............................(mm ) 469.900

Number of Bolts ....................................... 16.000
Bolt Diameter ....................................(mm ) 34.925
Bolt Initial Tightening Stress ............(lb./sq.in.)

Uncompressed Gasket Thickness ....................(mm ) 16.000

Grade of Attached B16_5 ANSI Flange.................... 1.100
Leak Pressure Ratio [m] ............................... 5.500
Effective Gasket Modulus ..................(Kg/sq.cm. ) 2062620.000

Externally Applied Moment ..... (optional) ....(Kg.m. ) 5000.000

Externally Applied Force ...... (optional) .......(Kg ) 2000.000
Pressure [P]...............................(Kg/sq.cm. ) 22.800

Disable Stress Calculations (Y/N) ..................... N

Flange Type (1-8, see ?-Help or Alt-P to plot) ........ 1.000

Flange Outside Diameter [A].......................(mm ) 545.000

Design Temperature ................................ C 150.000

Small End Hub Thickness [g0]......................(mm ) 12.700

Large End Hub Thickness [g1]......................(mm ) 60.185
Hub Length [h]....................................(mm ) 114.100

Flange Allowable @Design Temperature ......(lb./sq.in.) 20000.000

Flange Allowable @Ambient Temperature .....(lb./sq.in.) 20000.000
Flange Modulus of Elasticity @Design ......(Kg/sq.cm. ) 28288000.000
Flange Modulus of Elasticity @Ambient .....(Kg/sq.cm. ) 29500000.000
Bolt Allowable @Design Temperature ......(lb./sq.in.) 25000.000
Bolt Allowable @Ambient Temperature .....(lb./sq.in.) 25000.000
Gasket Seating Stress [y] .................(lb./sq.in.) 18000.000

Flange Allowable Stress Multiplier .................... 1.500

Bolt Allowable Stress Multiplier (VIII Div 2 4-141) ... 2.000

Disable Leakage Calculations (Y/N) .................... N

Disable ANSI B16.5 Checks (Y/N) ....................... N

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GUIDELINES FOR FLANGE Page10 of 48

LEAKAGE CALCULATION
g) Flange modulus of elasticity @ ambient : Refer table C-6 of B31.3 for flange
material and temperature.

h) Bolt allowable @ design temperature : Considered by CAESAR automatically as per

bolt material. (Alternatively refer table A2 of
B31.3 for corresponding bolt material and
temperature).

i) Bolt allowable @ ambient temperature : Considered by CAESAR automatically as per

bolt material. (Alternatively refer table A2 of
B31.3 for corresponding bolt material and
temperature).

j) Flange allowable stress multiplier : 1 (Refer para 2-8 of Section VIII Division 1)

k) Bolt allowable stress multiplier ( VIII DIV 2) : 2 (Refer article 4-141of Section VIII Division1)

3.5 Loads

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GUIDELINES FOR FLANGE Page14 of 48

LEAKAGE CALCULATION
leakage is predicted.) (Allowed/Actual)

Pressure Only (Ci-Creq)/Cp ............. 26.04

Force Only (Ci-Creq)/Cf ................ 245.82
Moment Only (Ci-Creq)/Cm ............... 8.28

Pressure+Force+Moment (Ci-Creq)/CL ..... 6.13

EQUIVALENT PRESSURE MODEL ----------------------------

Equivalent Pressure (Kg/sq.cm. ) ............ 96.88

ANSI B16.5 Flange Allowable Pressure Rating . 137.80

STRESS SAFETY FACTOR: (If less than one then joint

failure is predicted.) (Allowed/Actual)

ANSI B16.5/Equivalent Pressure ................. 1.42

ASME SECT VIII DIV 1 STRESS MODEL ------------------------

ACCORDING TO A93 APPENDIX S, THE FOLLOWING RIGIDITY

FACTORS SHOULD BE LESS THAN 1.0

ASME Rigidity Factor "J", Operating Case ....... 0.0074

ASME Rigidity Factor "J", Seating Case ......... 0.1012

CALCULATED STRESSES (lb./sq.in.)

OPERATING ALLOW SEATING ALLOW

--------- ----- ------- -----

Longitudinal Hub .. 8452 30000 12036 30000

Radial Flange ..... 11581 30000 16492 20000
Tangential Flange . 5481 30000 7806 20000
Maximum Average ... 10016 20000 14264 20000
Bolting ........... 9988 50000 2137 25000

"*" Indicates Failure for an item.

STRESS SAFETY FACTOR: (If less than one then joint

failure is predicted.) (Allowed/Actual)

OPERATING SEATING
--------- -------

Longitudinal Hub .... 3.55 2.49

Radial Flange ....... 2.59 1.21
Tangential Flange ... 5.47 2.56
Maximum Average ..... 2.00 1.40
Bolting ............. 5.01 11.70

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GUIDELINES FOR FLANGE Page15 of 48

LEAKAGE CALCULATION
Failure report sample:

FLANGE LEAKAGE/STRESS CALCULATIONS

Flange Inside Diameter [B] (User to verify) ......(mm ) 247.630
Flange Thickness [t]..............................(mm.) 69.900
Flange Rating (Optional) .............................. 900.000

Bolt Circle Diameter .............................(mm ) 469.900

Number of Bolts ....................................... 16.000
Bolt Diameter ....................................(mm ) 34.925
Bolt Initial Tightening Stress ............(lb./sq.in.)

Uncompressed Gasket Thickness ....................(mm ) 16.000

Grade of Attached B16_5 ANSI Flange.................... 1.100
Leak Pressure Ratio [m] ............................... 5.500
Effective Gasket Modulus ..................(Kg/sq.cm. ) 2062620.000

Externally Applied Moment ..... (optional) ....(Kg.m. ) 15000.000

Externally Applied Force ...... (optional) .......(Kg ) 8000.000
Pressure [P]...............................(Kg/sq.cm. ) 22.800

Disable Stress Calculations (Y/N) ..................... N

Flange Type (1-8, see ?-Help or Alt-P to plot) ........ 1.000

Flange Outside Diameter [A].......................(mm ) 545.000

Design Temperature ................................ C 150.000

Small End Hub Thickness [g0]......................(mm ) 12.700

Large End Hub Thickness [g1]......................(mm ) 60.185
Hub Length [h]....................................(mm ) 114.100

Flange Allowable @Design Temperature ......(lb./sq.in.) 20000.000

Flange Allowable @Ambient Temperature .....(lb./sq.in.) 20000.000
Flange Modulus of Elasticity @Design ......(Kg/sq.cm. ) 28288000.000
Flange Modulus of Elasticity @Ambient .....(Kg/sq.cm. ) 29500000.000
Bolt Allowable @Design Temperature ......(lb./sq.in.) 25000.000
Bolt Allowable @Ambient Temperature .....(lb./sq.in.) 25000.000
Gasket Seating Stress [y] .................(lb./sq.in.) 18000.000

Flange Allowable Stress Multiplier .................... 1.500

Bolt Allowable Stress Multiplier (VIII Div 2 4-141) ... 2.000

Disable Leakage Calculations (Y/N) .................... N

Disable ANSI B16.5 Checks (Y/N) ....................... N
Flange Face OD or Lapjt Cnt OD....................(mm ) 362.000
Flange Face ID or Lapjt Cnt ID....................(mm ) 248.000
Gasket Outer Diameter ............................(mm ) 334.980

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GUIDELINES FOR FLANGE Page16 of 48

LEAKAGE CALCULATION
Gasket Inner Diameter ............................(mm ) 312.720
Nubbin Width .....................................(mm ) 11.130
Facing Sketch ......................................... 9.000
Facing Column ......................................... 1.000

Flange Type: (Integral Weld Neck)

Effective gasket width parameters:

Effective gasket seating width, b......(mm ) 1.3913
Diameter of gasket load reaction, G....(mm ) 323.8500

SAFETY FACTOR SUMMARY for the different Flange Models

analyzed. (SAFETY FACTOR = Allowed/Actual)
SAFETY
FACTOR
Flexibility/Gasket Compression Model (Leakage).. 2.40
ANSI B16.5/Equivalent Pressure (Stress)......... 0.56
ASME Model Operating (Stress)................... 0.79
ASME Model Seating (Stress)..................... 0.85

FLANGE FLEXIBILITY MODEL ---------------------------------

BOLTED FLANGE CHARACTERISTICS:

Initial Tightening Stress in the Bolt (Not the seating

stress): 38376 lb./sq.in.

Approximate Torque required to induce the above initial

stress: 141 Kg.m.

GASKET COMPRESSION: COMPRESSION

(mm )
After Initial Boltup (Ci)........... 0.1128271595

Loss-of due to Pressure (Cp)........ 0.0042581009

Loss-of due to Applied Moment (Cm).. 0.0401539914
Loss-of due to Applied Force (Cf)... 0.0018042764
Loss-of due to all loads (CL)....... 0.0462163687

Initial minus all Losses (Ci-CL).... 0.0666107908

For Leak-Proof Joint (Creq)......... 0.0019454866
Excess available (Ci-Creq) ......... 0.1108816788

LEAKAGE SAFETY FACTOR: (If less than one then joint

leakage is predicted.) (Allowed/Actual)

Pressure Only (Ci-Creq)/Cp ............. 26.04

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GUIDELINES FOR FLANGE Page13 of 48

LEAKAGE CALCULATION
Flange Face OD or Lapjt Cnt OD....................(mm ) 362.000
Flange Face ID or Lapjt Cnt ID....................(mm ) 248.000
Gasket Outer Diameter ............................(mm ) 334.980
Gasket Inner Diameter ............................(mm ) 312.720
Nubbin Width .....................................(mm ) 11.130
Facing Sketch ......................................... 9.000
Facing Column ......................................... 1.000

Flange Type: (Integral Weld Neck)

Effective gasket width parameters:

Effective gasket seating width, b......(mm ) 1.3913
Diameter of gasket load reaction, G....(mm ) 323.8500

SAFETY FACTOR SUMMARY for the different Flange Models

analyzed. (SAFETY FACTOR = Allowed/Actual)
SAFETY
FACTOR
Flexibility/Gasket Compression Model (Leakage).. 6.13
ANSI B16.5/Equivalent Pressure (Stress)......... 1.42
ASME Model Operating (Stress)................... 2.00
ASME Model Seating (Stress)..................... 1.21

FLANGE FLEXIBILITY MODEL ---------------------------------

BOLTED FLANGE CHARACTERISTICS:

Initial Tightening Stress in the Bolt (Not the seating

stress): 38376 lb./sq.in.

Approximate Torque required to induce the above initial

stress: 141 Kg.m.

GASKET COMPRESSION: COMPRESSION

(mm )
After Initial Boltup (Ci)........... 0.1128271595

Loss-of due to Pressure (Cp)........ 0.0042581009

Loss-of due to Applied Moment (Cm).. 0.0133846644
Loss-of due to Applied Force (Cf)... 0.0004510691
Loss-of due to all loads (CL)....... 0.0180938356

Initial minus all Losses (Ci-CL).... 0.0947333276

For Leak-Proof Joint (Creq)......... 0.0019454866
Excess available (Ci-Creq) ......... 0.1108816788

LEAKAGE SAFETY FACTOR: (If less than one then joint

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GUIDELINES FOR FLANGE Page14 of 48

LEAKAGE CALCULATION
leakage is predicted.) (Allowed/Actual)

Pressure Only (Ci-Creq)/Cp ............. 26.04

Force Only (Ci-Creq)/Cf ................ 245.82
Moment Only (Ci-Creq)/Cm ............... 8.28

Pressure+Force+Moment (Ci-Creq)/CL ..... 6.13

EQUIVALENT PRESSURE MODEL ----------------------------

Equivalent Pressure (Kg/sq.cm. ) ............ 96.88

ANSI B16.5 Flange Allowable Pressure Rating . 137.80

STRESS SAFETY FACTOR: (If less than one then joint

failure is predicted.) (Allowed/Actual)

ANSI B16.5/Equivalent Pressure ................. 1.42

ASME SECT VIII DIV 1 STRESS MODEL ------------------------

ACCORDING TO A93 APPENDIX S, THE FOLLOWING RIGIDITY

FACTORS SHOULD BE LESS THAN 1.0

ASME Rigidity Factor "J", Operating Case ....... 0.0074

ASME Rigidity Factor "J", Seating Case ......... 0.1012

CALCULATED STRESSES (lb./sq.in.)

OPERATING ALLOW SEATING ALLOW

--------- ----- ------- -----

Longitudinal Hub .. 8452 30000 12036 30000

Radial Flange ..... 11581 30000 16492 20000
Tangential Flange . 5481 30000 7806 20000
Maximum Average ... 10016 20000 14264 20000
Bolting ........... 9988 50000 2137 25000

"*" Indicates Failure for an item.

STRESS SAFETY FACTOR: (If less than one then joint

failure is predicted.) (Allowed/Actual)

OPERATING SEATING
--------- -------

Longitudinal Hub .... 3.55 2.49

Radial Flange ....... 2.59 1.21
Tangential Flange ... 5.47 2.56
Maximum Average ..... 2.00 1.40
Bolting ............. 5.01 11.70

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
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GUIDELINES FOR FLANGE Page15 of 48

LEAKAGE CALCULATION
Failure report sample:

FLANGE LEAKAGE/STRESS CALCULATIONS

Flange Inside Diameter [B] (User to verify) ......(mm ) 247.630
Flange Thickness [t]..............................(mm.) 69.900
Flange Rating (Optional) .............................. 900.000

Bolt Circle Diameter .............................(mm ) 469.900

Number of Bolts ....................................... 16.000
Bolt Diameter ....................................(mm ) 34.925
Bolt Initial Tightening Stress ............(lb./sq.in.)

Uncompressed Gasket Thickness ....................(mm ) 16.000

Grade of Attached B16_5 ANSI Flange.................... 1.100
Leak Pressure Ratio [m] ............................... 5.500
Effective Gasket Modulus ..................(Kg/sq.cm. ) 2062620.000

Externally Applied Moment ..... (optional) ....(Kg.m. ) 15000.000

Externally Applied Force ...... (optional) .......(Kg ) 8000.000
Pressure [P]...............................(Kg/sq.cm. ) 22.800

Disable Stress Calculations (Y/N) ..................... N

Flange Type (1-8, see ?-Help or Alt-P to plot) ........ 1.000

Flange Outside Diameter [A].......................(mm ) 545.000

Design Temperature ................................ C 150.000

Small End Hub Thickness [g0]......................(mm ) 12.700

Large End Hub Thickness [g1]......................(mm ) 60.185
Hub Length [h]....................................(mm ) 114.100

Flange Allowable @Design Temperature ......(lb./sq.in.) 20000.000

Flange Allowable @Ambient Temperature .....(lb./sq.in.) 20000.000
Flange Modulus of Elasticity @Design ......(Kg/sq.cm. ) 28288000.000
Flange Modulus of Elasticity @Ambient .....(Kg/sq.cm. ) 29500000.000
Bolt Allowable @Design Temperature ......(lb./sq.in.) 25000.000
Bolt Allowable @Ambient Temperature .....(lb./sq.in.) 25000.000
Gasket Seating Stress [y] .................(lb./sq.in.) 18000.000

Flange Allowable Stress Multiplier .................... 1.500

Bolt Allowable Stress Multiplier (VIII Div 2 4-141) ... 2.000

Disable Leakage Calculations (Y/N) .................... N

Disable ANSI B16.5 Checks (Y/N) ....................... N
Flange Face OD or Lapjt Cnt OD....................(mm ) 362.000
Flange Face ID or Lapjt Cnt ID....................(mm ) 248.000
Gasket Outer Diameter ............................(mm ) 334.980

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GUIDELINES FOR FLANGE Page20 of 48

LEAKAGE CALCULATION
5.3 Analysis

Analysis tab shall be selected from Flange Analysis dialog box. Analysis tab can be used to
define the general analysis options, e.g. the flange attachment, material library, analysis method
etc. Following available fields on the analysis tab shall be defined.

1. Point name : This field is read-only.

2. No. : This field is read-only.

3. Flange type : This field is read-only.

4. Flange rating : This field is read-only.

5. Nom. pipe size : This field is read-only.

6. Tag no. : This field is read-only.

7. Attachment : Select from drop down list, shall be as per PMS.

8. Analysis method : Select from drop down list, shall be

ASME Section VIII Div. 1.

9. Gasket seating bolt load : Select from drop down list, shall be Code required.

10. Consider bolt spacing correction : Shall be enabled to consider the bolt spacing
correction factor in the analysis. [This option does not
apply to the ANSI check analysis method]

11. Analyze : Shall be enabled to include the flange in the analysis.

12. Max. ratio : This field is read-only.

13. Notes : This field is read-only.

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GUIDELINES FOR FLANGE Page21 of 48

LEAKAGE CALCULATION
4.4 Load

The Load tab shall be used to define the loads applied to each flange, including any external
loads (optional). Following available fields on the load tab shall be defined.

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GUIDELINES FOR FLANGE Page22 of 48

LEAKAGE CALCULATION

1. Point name : This field is read-only.

2. No. : This field is read-only.

3. Flange rating : This field is read-only.

4. Nom. Pipe size : This field is read-only.

5. Load combination : Shall be selected from the drop down list to determine the
applied external loads, i.e. axial force & bending moment.

6. Operating case : Operating case shall be selected from the drop down
list to draw the operating pressure and temperature
cases.

7. Operating pressure : Operating press. shall be entered. [ Editable when the

operating case field is set to User. Otherwise, this
field is read-only.

8. Apply B31.3 uninsulated temp. : Shall be selected to use reduced temp., as defined in
section 301.3.2 of B31.3, when determining the
allowable stresses.

9. Operating temperature : Operating temp. shall be entered [ Editable when the

Operating case field is set to user. Otherwise, this
field is read-only].

10. Ambient temperature : This field is read-only.

11. External pressure : This field is optional. An external pressure is not

required to execute the flange analysis.

12. Applied force combination : Force combination shall be selected from the drop
down list to draw the axial force .

13. Axial force : Axial force shall be entered to calculate moment

due to external loads.[ Editable when the Load
combination field is set to user. Otherwise,
this field is read - only]

14. Applied moment combination : Applied moment combination Shall be selected from the
drop down list to draw the bending moment .

15. Bending moment : Bending moment shall be entered. [ Editable when

the Load combination field is set to user.
otherwise, this field is read-only]

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GUIDELINES FOR FLANGE Page23 of 48

LEAKAGE CALCULATION
4.5 Flange

The Flange tab shall be used to define the entire flange dimension, material properties and
additional attributes i.e. attachment, reverse, ring type. Following available fields on the flange
tab shall be defined.

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GUIDELINES FOR FLANGE Page24 of 48

LEAKAGE CALCULATION

1. Point name : This field is read-only.

2. No. : This field is read- only.

3. Flange type : This field is read- only.

4. Flange rating : This field is read- only.

5. Attachment : Flange attachment type shall be selected from the drop

down list.

6. Joint efficiency factor : Joint efficiency factor shall be entered only for blind flanges.

7. Lap contact OD : Outside diameter of the stub flange shall be

entered. This field is only available for lap joint flanges.

8. Ring type : Ring type shall be selected from the drop down list.
this option is only available for lap joint and slip-on,
with loose attachment, flanges.

9. Reverse : This field shall be checked to consider the flange as a

reversed flange.(not used normally.)

10. Flange material library : Material library shall be selected from the drop down
list.

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GUIDELINES FOR FLANGE Page25 of 48

LEAKAGE CALCULATION

11. Flange material : Select from the drop down list, shall be as per PMS.

12. Select material : Select the flange material using the ASME material
properties dialog, shall be as per PMS.

13. Flange/ Bolt dimensions : Select the dimension library.

14. Nom. Pipe size : This field is read-only.

15. Rigidity factor : Flange rigidity factor shall be entered. This field does
not apply to blind flanges.
KI = Rigidity factor for integral or optional
flange types = 0.3
KL= Rigidity factor for loose type flanges = 0.2

16. Outside diameter [A] : Considered by AutoPIPE automatically as per

selected flange /bolt dimensions library
(B16.5/B16.47).

17. Inside diameter [B] : Considered by AutoPIPE automatically as per

selected flange /bolt dimensions library
(B16.5/B16.47).

18. Thickness [Tf] : Considered by AutoPIPE automatically as per

selected flange /bolt dimensions library
(B16.5/B16.47).

19. Hub length [Y- Tf] : Considered by AutoPIPE automatically as per

Selected flange /bolt dimensions library
(B16.5/B16.47).

20. Large end hub thickness [g1]
21. Small end hub thickness [g0]
: Considered by AutoPIPE automatically as per
selected flange /bolt dimensions library
(B16.5/B16.47).
: Considered by Auto PIPE automatically as per
Selected flange /bolt dimensions library
(B16.5/B16.47).

22. Allow. Stress at opera. temp. [sf] : Considered by Auto PIPE automatically as per
material selected. (Table A-1 of ASME B31.3).

23. Allow. Stress at Amb. temp. [sf] : Considered by Auto PIPE automatically as per
material selected. (Table A-1 of ASME B31.3).

24. Density : Considered by AutoPIPE automatically as per

material selected.

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GUIDELINES FOR FLANGE Page26 of 48

LEAKAGE CALCULATION
25. Elastic mod. at oper. temp. : Considered by AutoPIPE automatically as per
material selected. (Table C-6 of B31.3).

26. Elastic mod. at Amb. temp. : Considered by AutoPIPE automatically as per

material selected. (Table C-6 of B31.3).

4.6 Pipe
The Pipe tab shall be used to define the pipe material and allowable stresses, as well as
reference piping dimensions when designing the flange. Following available fields on the pipe
tab shall be defined.

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GUIDELINES FOR FLANGE Page27 of 48

LEAKAGE CALCULATION

1. Field title : This field is read only.

2. Point name : This field is read only.

3. No. : This field is read only.

4. Flange rating : This field is read only.

5. Pipe ID : This field is read only.

6. Pipe ID material : This field is read only.

7. Nom. Pipe size : This field is read only.

8. Pipe outside diameter : This field is read only.

9. Pipe inside diameter : This field is read only.

10. Pipe material library : Select Pipe material library to be used for pipe
allowable stresses from the drop down list.

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GUIDELINES FOR FLANGE Page28 of 48

LEAKAGE CALCULATION

11. Pipe material : Pipe material shall be selected from the drop down list.
(Note: This drop down list of materials is filtered based
on the material library selected on the Analysis tab.)

12. Select material : Pipe material shall be selected using the ASME material
properties dialog box.

13. Allow. Stress at oper. temp [Sn] : Read only, unless NS is selected as the pipe material.

14. Allow. Stress at Amb. temp [Sn] : Read only, unless NS is selected as the pipe material.

4.7 BOLTS
The bolts tab can be used to define the bolt material and allowable stresses, as well as the bolt
dimensions. Following available fields on the bolts tab shall be defined.

1. Point name : This field is read- only.

2. No. : This field is read- only.

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GUIDELINES FOR FLANGE Page29 of 48

LEAKAGE CALCULATION
3. Flange rating : This field is read-only.

4. Nom. pipe size : This field is read-only.

5. Bolt material : Bolt material shall be selected from the drop down list,
shall be as per PMS.
[Note: This drop down list of materials is filtered based
on the material library selected on the Analysis tab.]

6. Select material : Bolt material shall be selected using the ASME material
properties dialog, shall be as per PMS.

7. Thread type : Bolt thread type shall be selected.

8. Bolt circle diameter [C] : Considered by AutoPIPE automatically as per

B16.5/ B16.47.

9. Number of bolts : Considered by AutoPIPE automatically as per

B16.5/B16.47.

10. Nominal diameter : Considered by Auto PIPE automatically as per

B16.5/ B16.47.

11. Effective diameter : Considered by Auto PIPE automatically as per

B16.5/ B16.47.

12. Bolt hole diameter : Considered by Auto PIPE automatically as per

B16.5/ B16.47.

13. Allow. Stress at oper. temp [sb] : Considered by Auto PIPE automatically as per
material selected. (Table A-2 of ASME B31.3).

14. Allow. Stress at amb. temp [sa] : Considered by Auto PIPE automatically as per
material selected.(Table A-2 of ASME B31.3).

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GUIDELINES FOR FLANGE Page30 of 48

LEAKAGE CALCULATION
4.8 GASKET
The Gasket tab can be used to define the gasket material and allowable stresses, as well as
the gasket dimensions. Following available fields on the gasket tab shall be defined.

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GUIDELINES FOR FLANGE Page31 of 48

LEAKAGE CALCULATION
1. Field title : This field is read-only.

2. Point name : This field is read-only.

3. No. : This field is read-only.

4. Flange rating : This field is read-only.

5. Nom. Pipe size : This field is read-only.

6. Width [N] : Considered by Auto PIPE automatically as per

B16.20.

7. Inside diameter : Considered by Auto PIPE automatically as per

B16.20.

8. Gasket material : Gasket material shall be selected from the drop down
list, shall be as per PMS.

9. Configuration : Select the gasket configuration from the drop down list,
shall be as per section VIII Division 1 Appendix 2.
Table 2-5.2.

10. Gasket thickness : Considered by Auto PIPE automatically as per B16.20.

[Note: This field is only editable when the configuration
selected requires a gasket thickness to be defined.]

11. Nubbin width : Considered by Auto PIPE automatically as per B16.20

and Section VIII- Division 1 Appendix 2.
[Note: This field is only editable when the configuration
requires a nubbin width to be defined.]

12. Strength factor [m] : Considered by Auto PIPE automatically as per

Section VIII Division 1 Appendix 2, table 2-5.1.

13. Seating stress [y] : Considered by Auto PIPE automatically as per

Section VIII Division 1 Appendix 2, table 2-5.1.

14. Effective gasket seating width [b] : Considered by Auto PIPE automatically as per
Section VIII- Division 1 Appendix 2 & B16.20.
[Note: This field is editable.]

15. Full face gasket : Shall be selected to consider the gasket Full Faced.
[Note: This option is only available for the weld neck
flange type.]

16. Load react. Diameter [G] : Considered by Auto PIPE automatically.

[Note: This field is only editable when user is
selected as the gasket material.]

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GUIDELINES FOR FLANGE Page32 of 48

LEAKAGE CALCULATION
4.9 ANSI CHECK

ANSI Check fields get disabled when ASME Section VIII Division 1 is selected as the flange
Analysis method on the Analysis tab.

Notes:
1. ANSI check method shall be performed only when ANSI Check is selected as the flange
analysis method on the Analysis tab.

2. The ANSI flange check can only be executed for flanges set to NS rating when the User
pressure Temp. Data option is checked, i.e. when user P max data is used in the ANSI Check
analysis.

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GUIDELINES FOR FLANGE Page33 of 48

LEAKAGE CALCULATION

4.10 Analyze tab shall be selected for performing flange analysis.

4.11 Show report tab shall be selected for generating analysis output report.

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GUIDELINES FOR FLANGE Page34 of 48

LEAKAGE CALCULATION
4.12 Auto PIPE output report:

Pass report Sample:

--------------------------------------------------------------------------------------
--------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
--------------------------------------------------------------------------------------
--------------------------

* ******* ** ******* *******

*** ** ** ** ** ** ** **
** ** ****** ** ** ** ** ** **
** ** ** ** ** ***** ******* ** ******* *****
********* ** ** ** ** ** ** ** ** **
** ** ** ** ** ** ** ** ** ** **
** ** ***** ** ***** ** ** ** *******

Pipe Stress Analysis and Design Program

Version: 09.05.00.21

Edition: Plus

Developed and Maintained by

BENTLEY SYSTEMS, INCORPORATED

1600 Riviera Ave., Suite 300
Walnut Creek, CA 94596

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GUIDELINES FOR FLANGE Page35 of 48

LEAKAGE CALCULATION
-------------------------------------------------------------------------------------
---------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
-------------------------------------------------------------------------------------
---------------------------

************************************************************
** **
** AUTOPIPE FLANGE ANALYSIS **
** **
************************************************************

SYSTEM NAME : 01-0010 1

PROJECT ID : AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ

PREPARED BY : ______________________________
AP

CHECKED BY : ______________________________
SK

1ST APPROVER : ______________________________

DKD

2ND APPROVER : ______________________________

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GUIDELINES FOR FLANGE Page36 of 48

LEAKAGE CALCULATION
--------------------------------------------------------------------------------------
--------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
--------------------------------------------------------------------------------------
--------------------------

************************************************************
** **
** POINT A00 FLANGE # 1 **
** WELD-NECK **
** NPS 450.000 mm RATING 900 **
** **
************************************************************

VESSEL DESIGN CODE : ASME Section VIII 2010, Division 1

DIMENSION LIBRARY : FlangeDimLib.mdb

DIMENSION CODE : B16-5

MATERIAL LIBRARY : asme2010.mdb

FLANGE ATTACHMENT : INTEGRAL

FLANGE CONFIGURATION : WHOLE

I N P U T S

1.1 FLANGE:
------

Material : SA-105
Outside diameter, A : 787.400 mm Bore diameter, B : 431.800 mm
Thickness, tf : 101.600 mm Rigidity Factor, K : 0.300
Small End Hub Thk, g0: 12.7000 mm Large End Hub Thk, g1: 66.6750 mm
Hub Length, h : 127.000 mm Bolt Circle Dia., C : 685.800 mm
Allowable at Oper, Sf: 137.895 MPa Allowable at Amb, Sf : 137.895 MPa
Modulus. at Oper, E : 194845.8 MPa Modulus. at Amb, E : 199948.8 MPa

1.2 PIPE:
----

Material : A691-G2.25CR
Standard pipe library file : B313-06
Nominal diameter : 450.000 mm
Pipe schedule : XS
Pipe Inner Diameter : 431.800 mm Pipe Outer Diameter : 457.200 mm
Allowable at Oper, Sn: 125.898 MPa Allowable at Amb, Sn : 137.895 MPa

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GUIDELINES FOR FLANGE Page37 of 48

LEAKAGE CALCULATION

1.3 GASKET:
------

Gasket Type : Ring joint iron or soft steel

Gasket Config. : Sketch (6) - Column 1 of Table 2-5.2
Inside Diameter : 514.350 mm Seating Width, N : 19.050 mm
Width of Nubbin, w : 19.050 mm Gasket Thickness : 0.000 mm
Strength Factor, m : 5.500 Seating Stress, y : 124.106 MPa
Load Reaction Dia., G: 533.400 mm Eff. Press. Width, b: 2.381 mm

1.4 BOLTS:
-----
Material : SA-193-B16-1
No. of Bolts : 20 Min. Bolt Spacing : 101.6000 mm
Bolt Diameter : 47.6250 mm Eff. Bolt Diameter : 44.1884 mm
Hub Radial Dist. : 60.3250 mm Outer Edge Dist. : 47.6250 mm
Bolt Hole Diameter : 50.8000 mm
Allowable at Oper, Sb: 137.895 MPa Allowable at Amb, Sa : 137.895 MPa

1.5 PRESSURE & TEMPERATURE LOADS:

----------------------------
Internal pressure : 3.300 N/mm2 At temperature : 120.000 deg C
External pressure : 0.000 N/mm2 At temperature : -17.778 deg C
Ambient temp. : 21.100 deg C

D E S I G N

2.0 SUMMARY:
-------

Design code : ASME Section VIII Div. I 2010

Flange Thickness : 101.6000 mm

Flange Volume : 0.42E+08 mm**3 **Flange Weight : 191.994 kg

Flange Diameter : 787.400 mm Flange Bore : 431.800 mm
Polar Mom Inertia : 0.42E+08 mm4 Bend Mom Inertia : 0.35E+08
mm4
Bolt Circle Diameter : 685.800 mm Gasket Load Diameter : 533.400 mm
Gasket Strength Factor : 5.5000 Gasket Seating Stress : 124.106
MPa

**NOTE: This weight is not used in the static/dynamic analysis.

For lap flanges this weight is for the stub flange only.
This weight does not include any bolt or nut weight.
To set the weight use the Modify > Flange menu option.

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GUIDELINES FOR FLANGE Page38 of 48

LEAKAGE CALCULATION
--------------------------------------------------------------------------------------
--------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
--------------------------------------------------------------------------------------
R E S U L T S

3.1 ALLOWABLE STRESSES:

------------------

1. OPERATING CONDITIONS:
INT. PRESS ALLOWABLE INT. PRESS
MPa MPa RATIO
---------- --------- ----------
Longitudinal Hub Stress, SH = 32.090 206.843 0.155
Radial Flange Stress, SR = 27.159 137.895 0.197
Tangential Flange Stress,ST = 22.972 137.895 0.167
Average Stress, (SH+SR)/2.0 = 29.624 137.895 0.215
Average Stress, (SH+ST)/2.0 = 27.531 137.895 0.200
Bolt Tensile Stress = 28.765 137.895 0.209

**2. GASKET SEATING CONDITIONS:

INT. PRESS ALLOWABLE INT. PRESS
MPa MPa RATIO
---------- --------- ----------
Longitudinal Hub Stress, SH = 67.527 206.843 0.326
Radial Flange Stress, SR = 57.151 137.895 0.414
Tangential Flange Stress,ST = 48.340 137.895 0.351
Average Stress, (SH+SR)/2.0 = 62.339 137.895 0.452
Average Stress, (SH+ST)/2.0 = 57.934 137.895 0.420
Bolt Tensile Stress = 86.697 137.895 0.629

**NOTE: The gasket seating condition stresses are calculated using the full available
bolt load,
where Wg = [(Am + Ab)*Sa]/2.

3.2 RIGIDITY CRITERION:

------------------

1. OPERATING CONDITIONS:
INT. PRESS ALLOWABLE INT. PRESS
RATIO
---------- --------- ----------
Rigidity Index, J = 0.092 1.000 0.092

2. GASKET SEATING CONDITIONS:

INT. PRESS ALLOWABLE INT. PRESS
RATIO
---------- --------- ----------
Rigidity Index, J = 0.188 1.000 0.188

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L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
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Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page34 of 48

LEAKAGE CALCULATION
4.12 Auto PIPE output report:

Pass report Sample:

--------------------------------------------------------------------------------------
--------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
--------------------------------------------------------------------------------------
--------------------------

* ******* ** ******* *******

*** ** ** ** ** ** ** **
** ** ****** ** ** ** ** ** **
** ** ** ** ** ***** ******* ** ******* *****
********* ** ** ** ** ** ** ** ** **
** ** ** ** ** ** ** ** ** ** **
** ** ***** ** ***** ** ** ** *******

Pipe Stress Analysis and Design Program

Version: 09.05.00.21

Edition: Plus

Developed and Maintained by

BENTLEY SYSTEMS, INCORPORATED

1600 Riviera Ave., Suite 300
Walnut Creek, CA 94596

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page35 of 48

LEAKAGE CALCULATION
-------------------------------------------------------------------------------------
---------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
-------------------------------------------------------------------------------------
---------------------------

************************************************************
** **
** AUTOPIPE FLANGE ANALYSIS **
** **
************************************************************

SYSTEM NAME : 01-0010 1

PROJECT ID : AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ

PREPARED BY : ______________________________
AP

CHECKED BY : ______________________________
SK

1ST APPROVER : ______________________________

DKD

2ND APPROVER : ______________________________

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page36 of 48

LEAKAGE CALCULATION
--------------------------------------------------------------------------------------
--------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
--------------------------------------------------------------------------------------
--------------------------

************************************************************
** **
** POINT A00 FLANGE # 1 **
** WELD-NECK **
** NPS 450.000 mm RATING 900 **
** **
************************************************************

VESSEL DESIGN CODE : ASME Section VIII 2010, Division 1

DIMENSION LIBRARY : FlangeDimLib.mdb

DIMENSION CODE : B16-5

MATERIAL LIBRARY : asme2010.mdb

FLANGE ATTACHMENT : INTEGRAL

FLANGE CONFIGURATION : WHOLE

I N P U T S

1.1 FLANGE:
------

Material : SA-105
Outside diameter, A : 787.400 mm Bore diameter, B : 431.800 mm
Thickness, tf : 101.600 mm Rigidity Factor, K : 0.300
Small End Hub Thk, g0: 12.7000 mm Large End Hub Thk, g1: 66.6750 mm
Hub Length, h : 127.000 mm Bolt Circle Dia., C : 685.800 mm
Allowable at Oper, Sf: 137.895 MPa Allowable at Amb, Sf : 137.895 MPa
Modulus. at Oper, E : 194845.8 MPa Modulus. at Amb, E : 199948.8 MPa

1.2 PIPE:
----

Material : A691-G2.25CR
Standard pipe library file : B313-06
Nominal diameter : 450.000 mm
Pipe schedule : XS
Pipe Inner Diameter : 431.800 mm Pipe Outer Diameter : 457.200 mm
Allowable at Oper, Sn: 125.898 MPa Allowable at Amb, Sn : 137.895 MPa

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page37 of 48

LEAKAGE CALCULATION

1.3 GASKET:
------

Gasket Type : Ring joint iron or soft steel

Gasket Config. : Sketch (6) - Column 1 of Table 2-5.2
Inside Diameter : 514.350 mm Seating Width, N : 19.050 mm
Width of Nubbin, w : 19.050 mm Gasket Thickness : 0.000 mm
Strength Factor, m : 5.500 Seating Stress, y : 124.106 MPa
Load Reaction Dia., G: 533.400 mm Eff. Press. Width, b: 2.381 mm

1.4 BOLTS:
-----
Material : SA-193-B16-1
No. of Bolts : 20 Min. Bolt Spacing : 101.6000 mm
Bolt Diameter : 47.6250 mm Eff. Bolt Diameter : 44.1884 mm
Hub Radial Dist. : 60.3250 mm Outer Edge Dist. : 47.6250 mm
Bolt Hole Diameter : 50.8000 mm
Allowable at Oper, Sb: 137.895 MPa Allowable at Amb, Sa : 137.895 MPa

1.5 PRESSURE & TEMPERATURE LOADS:

----------------------------
Internal pressure : 3.300 N/mm2 At temperature : 120.000 deg C
External pressure : 0.000 N/mm2 At temperature : -17.778 deg C
Ambient temp. : 21.100 deg C

D E S I G N

2.0 SUMMARY:
-------

Design code : ASME Section VIII Div. I 2010

Flange Thickness : 101.6000 mm

Flange Volume : 0.42E+08 mm**3 **Flange Weight : 191.994 kg

Flange Diameter : 787.400 mm Flange Bore : 431.800 mm
Polar Mom Inertia : 0.42E+08 mm4 Bend Mom Inertia : 0.35E+08
mm4
Bolt Circle Diameter : 685.800 mm Gasket Load Diameter : 533.400 mm
Gasket Strength Factor : 5.5000 Gasket Seating Stress : 124.106
MPa

**NOTE: This weight is not used in the static/dynamic analysis.

For lap flanges this weight is for the stub flange only.
This weight does not include any bolt or nut weight.
To set the weight use the Modify > Flange menu option.

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page38 of 48

LEAKAGE CALCULATION
--------------------------------------------------------------------------------------
--------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
--------------------------------------------------------------------------------------
R E S U L T S

3.1 ALLOWABLE STRESSES:

------------------

1. OPERATING CONDITIONS:
INT. PRESS ALLOWABLE INT. PRESS
MPa MPa RATIO
---------- --------- ----------
Longitudinal Hub Stress, SH = 32.090 206.843 0.155
Radial Flange Stress, SR = 27.159 137.895 0.197
Tangential Flange Stress,ST = 22.972 137.895 0.167
Average Stress, (SH+SR)/2.0 = 29.624 137.895 0.215
Average Stress, (SH+ST)/2.0 = 27.531 137.895 0.200
Bolt Tensile Stress = 28.765 137.895 0.209

**2. GASKET SEATING CONDITIONS:

INT. PRESS ALLOWABLE INT. PRESS
MPa MPa RATIO
---------- --------- ----------
Longitudinal Hub Stress, SH = 67.527 206.843 0.326
Radial Flange Stress, SR = 57.151 137.895 0.414
Tangential Flange Stress,ST = 48.340 137.895 0.351
Average Stress, (SH+SR)/2.0 = 62.339 137.895 0.452
Average Stress, (SH+ST)/2.0 = 57.934 137.895 0.420
Bolt Tensile Stress = 86.697 137.895 0.629

**NOTE: The gasket seating condition stresses are calculated using the full available
bolt load,
where Wg = [(Am + Ab)*Sa]/2.

3.2 RIGIDITY CRITERION:

------------------

1. OPERATING CONDITIONS:
INT. PRESS ALLOWABLE INT. PRESS
RATIO
---------- --------- ----------
Rigidity Index, J = 0.092 1.000 0.092

2. GASKET SEATING CONDITIONS:

INT. PRESS ALLOWABLE INT. PRESS
RATIO
---------- --------- ----------
Rigidity Index, J = 0.188 1.000 0.188

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page39 of 48

LEAKAGE CALCULATION
--------------------------------------------------------------------------------------
--------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:18 AM AutoPIPE Plus
9.5.0.21
--------------------------------------------------------------------------------------
--------------------------

S T R E S S F A C T O R S

4.1 DUE TO FLANGE DIAMETER:

----------------------

K = 1.8235 T = 1.5749
Z = 1.8601 Y = 3.4019
U = 3.7383
e = 0.0071 1/mm
d = 2238410. mm**3
ho = 74.0531 mm
Lambda = 1.563

4.2 DUE TO FLANGE HUB:

-----------------

h/ho = 43.5606
G1/G0 = 5.2500
F = 0.5276
V = 0.0199
f = 1.0000

F O R C E S & M O M E N T S

5.1 DUE TO INTERNAL PRESSURE:

------------------------

Total hydrostatic end force, H = 737411.1 N

Minimum operating bolt load, Wm1 = 882259.7 N
Min. gasket seating bolt load, Wm2 = 495221.2 N
Design gasket seating bolt load, Wg = 2659136. N
Ring type moment factor, Fs = 1.0000
Bolt spacing correction factor, Bsc = 1.0000

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page40 of 48

LEAKAGE CALCULATION

Mom. Arm x Force = Moment*Bsc*Fs

mm N N.m
-------- -------- -----------------

Hydrostatic end force moment, MD = hd x Hd

93.662 x 483246.8 = 45262.19

Diff. hydrostatic force moment, MT = ht x Ht

101.600 x 254164.4 = 25823.15

Operating gasket load moment, MG = hg x Hg

76.200 x 144848.6 = 11037.48

Total gasket seating moment, Mg = hg x Wg

76.200 x 2659136. = 202626.6

Ext. Bending & Ax. force moment Moe = 4Me.(xr) + Fa.hD = Moment*Fs
14167.04 + 0.000 = 14167.04

Where, xr = [I/(0.3846*Ip+I)]*[hD/(C-2*hD)]

Total operating moment, MO=MD+MT+MG+Moe = 96289.86 N.m

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page41 of 48

LEAKAGE CALCULATION
Failure report Sample:

-------------------------------------------------------------------------------------
---------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:32 AM AutoPIPE Plus
9.5.0.21
-------------------------------------------------------------------------------------
---------------------------

* ******* ** ******* *******

*** ** ** ** ** ** ** **
** ** ****** ** ** ** ** ** **
** ** ** ** ** ***** ******* ** ******* *****
********* ** ** ** ** ** ** ** ** **
** ** ** ** ** ** ** ** ** ** **
** ** ***** ** ***** ** ** ** *******

Pipe Stress Analysis and Design Program

Version: 09.05.00.21

Edition: Plus

Developed and Maintained by

BENTLEY SYSTEMS, INCORPORATED

1600 Riviera Ave., Suite 300
Walnut Creek, CA 94596

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page42 of 48

LEAKAGE CALCULATION
-------------------------------------------------------------------------------------
---------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:32 AM AutoPIPE Plus
9.5.0.21
-------------------------------------------------------------------------------------
---------------------------

************************************************************
** **
** AUTOPIPE FLANGE ANALYSIS **
** **
************************************************************

SYSTEM NAME : 01-0010 1

PROJECT ID : AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ

PREPARED BY : ______________________________
AP

CHECKED BY : ______________________________
SK

1ST APPROVER : ______________________________

DKD

2ND APPROVER : ______________________________

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0
 Document No
L&T Engineering , Faridabad Rev 0A
PD-DP-0005

GUIDELINES FOR FLANGE Page43 of 48

LEAKAGE CALCULATION
-------------------------------------------------------------------------------------
---------------------------
01-0010 1
05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY
10:32 AM AutoPIPE Plus
9.5.0.21
-------------------------------------------------------------------------------------
---------------------------

************************************************************
** **
** POINT A00 FLANGE # 1 **
** WELD-NECK **
** NPS 450.000 mm RATING 900 **
** **
************************************************************

VESSEL DESIGN CODE : ASME Section VIII 2010, Division 1

DIMENSION LIBRARY : FlangeDimLib.mdb

DIMENSION CODE : B16-5

MATERIAL LIBRARY : asme2010.mdb

FLANGE ATTACHMENT : INTEGRAL

FLANGE CONFIGURATION : WHOLE

I N P U T S

1.1 FLANGE:
------

Material : SA-105
Outside diameter, A : 787.400 mm Bore diameter, B : 431.800 mm
Thickness, tf : 101.600 mm Rigidity Factor, K : 0.300
Small End Hub Thk, g0: 12.7000 mm Large End Hub Thk, g1: 66.6750 mm
Hub Length, h : 127.000 mm Bolt Circle Dia., C : 685.800 mm
Allowable at Oper, Sf: 137.895 MPa Allowable at Amb, Sf : 137.895 MPa
Modulus. at Oper, E : 201975.8 MPa Modulus. at Amb, E : 199948.8 MPa

1.2 PIPE:
----

Material : A691-G2.25CR
Standard pipe library file : B313-06
Nominal diameter : 450.000 mm
Pipe schedule : XS
Pipe Inner Diameter : 431.800 mm Pipe Outer Diameter : 457.200 mm
Allowable at Oper, Sn: 137.895 MPa Allowable at Amb, Sn : 137.895 MPa

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server.
L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used,
disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved.
Format EN-FT-4061, Rev 0