Flanges The Problems,

Problems Selection and Design

considerations
The obvious problem is simply leakage that occurs at some
stage
Let us look at the statistics

04/27/15

Flanges The Problems

The obvious problem is simply leakage that occurs at some
stage
Let us look at the
Look at that 2%
statistics
Clearly leakage is a serious problem for industry

04/27/15

Flanges
We
look atThe
some
Problems
of the reasons why leakage occurs
The obvious problem is simply leakage that occurs at some
stage
Let us look at the
statistics
Clearly leakage is a serious problem for industry
So, logically, we should start with the reasons why leakage
occurs

04/27/15

We look at some of the reasons why leakage occurs

First we look at the components of a Flange System
Those are all the components of the flange system
Sole purpose of the bolts is to maintain a squeeze on the
gasket
Bolting
Gasket
Flange

04/27/15

We look at some of the reasons why leakage occurs

First we look at the components of a Flange System
Those are all the components of the flange system
Sole purpose of the bolts is to maintain a squeeze on the
gasket
Here is the gasket squeezing force on the upper flange

04/27/15

We look at some of the reasons why leakage occurs

Firstbolt
The
we look
supplies
at the
the
components
squeeze onof
the
a Flange
gasket System
Those are all the components of the flange system
Sole purpose of the bolts is to maintain a squeeze on the
gasket
Here is the gasket squeezing force on the upper flange

04/27/15

We look at some of the reasons why leakage occurs

Let us
The
bolt
balance
supplies
thethe
3 forces
squeeze
on on
thethe
flange
gasket
in a simple
equation
Internal pressure gives rise to other forces
There are now 3 forces acting on the
flange

2 up and 1
down

Bolt force

P
Pressure
force

04/27/15

Gasket force

We look at some of the reasons why leakage occurs

Let us balance the 3 forces on the flange in a simple
equation
The bolt has to balance the gasket and pressure forces
This gives rise to our first equation

Bolt force

P
Pressure
force

Gasket force

Turning this equation around:

Bolt force = Gasket force
04/27/15

Pressure force
8

We look at some of the reasons why leakage occurs

If
Let
the
usBolt
balance
forcethe
= Pressure
3 forces on
force
the: flange
No Gasket
in a squeeze
simple
occurs
equation
The bolt has to balance the gasket and pressure forces
This gives rise to our first equation

Bolt force

P
Pressure
force

Gasket force

Turning this equation around:

Gasket
force
= Bolt force
Bolt force
= Gasket
04/27/15

- Pressure
+
Pressureforce
force
9

We look at some of the reasons why leakage occurs

If
the
Pressure
force
: No Gasket
squeeze
Let
usBolt
lookforce
more=closely
at the
gasket
between
the flanges
occurs
The flange releases the gasket leakage occurs !

Bolt force

P
Pressure
force

Gasket force

Turning this equation around:

Gasket force = Bolt force
04/27/15

Pressure force
10

Thelook
We
equation
at some
is adjusted
of the reasons
to takewhy
intoleakage
accountoccurs
the
rotation
Let us look more closely at the gasket between the flanges
The bolts act as a hinge flanges rotate from bolt and
pressure forces
Leakage can occur

Gasket force = Bolt force

04/27/15

Pressure force
11

Let us
The
equation
consider
is the
adjusted
residual
to take
gasket
into
squeeze
account the
rotation
Each component of the equation reduces gasket
squeeze
This is an extremely important point
Now we consider what is required of the gasket

Gasket force = Bolt force

04/27/15

Pressure force
- Rotation
12

Let us consider the residual gasket squeeze

Bolt
- Pressure
- Rotation of the
force
force
flange
What should this residual force be ?

= Final Gasket
force

Tighte
n bolts
Force reduction from pressure

Gasket
force

04/27/15

ForceResidual
reduction
orfrom
finalflange
gasketrotation
force

13

Let us consider the residual gasket squeeze

Consider a- flange
Bolt
Pressure
with the
- gasket
Rotation
properly
of the seated
= Final Gasket
force
force
flange
force
What should this residual force be ?
Tighte
Let
n bolts

us approach the residual force using some simple

logic

Gasket
force

04/27/15

Residual or final gasket

force

14

Let us consider the residual gasket squeeze

Gasket pressure must exceed the fluid pressure for success
Consider a flange with the gasket properly seated
Fluid under pressure it trying to escape bypass the
gasket
But there is pressure or squeeze on the gasket
If the pressure on the gasket is less than fluid pressure
leakage occurs

04/27/15

15

So far
Let
us we
consider
have considered
the residualMechanical
gasket squeeze
problems with
leakage
Gasket pressure must exceed the fluid pressure for success
We use a factor (from the code) m greater than 1.0
Residual gasket pressure is therefore

mxP

04/27/15

mx
P

16

So far we have considered Mechanical problems with

leakage
The difficult
Consider
another
problems
mechanical
are thermal
problem
in nature
an external
moment
Consider what happens when one flange is hotter than the
other
It walks over the gasket causing it to degrade
This a particularly difficult problem with heat exchangers

04/27/15

17

Wefar
So
now
we
consider
have considered
the forcesMechanical
acting on the
problems
flange with
under
leakage
pressure
Consider another mechanical problem an external
moment
Flange rotation can occur
The path for possible leakage is obvious
The gasket is unevenly loaded code rules are not
accurate
We come back to external loads later on

04/27/15

18

We now consider the forces acting on the flange under

pressure
ForceW
inside
the bore from pressure
Thus
m1 = HD + HP + HT

HD

Force to squeeze the gasket

HP

Force on the annular space

HT

These forces are balanced by the bolt for Wm1

Wm1

HD HT
04/27/15

HP
19

We now consider the moment

forces acting
acting
onon
the
the
flange
flange
under
under
pressure
Thus Wm1 = HD + HP + HT

Wm1 is the OPERATING bolt force

Wm1

HD HT
04/27/15

HP
20

We now consider the moment

force acting
acting
on the
on the
flange
flange
for under
gasket
pressure
tightening
Here are the moment arms the bolt acting as a hinge
The moment on the flange:

MO = HD.hD +HT.hT + HP.hG

Wm1

hG
hT
HD HT

hD

04/27/15

HP
21

We now consider the force acting on the flange for gasket

tightening
This is the initial squeeze on the gasket and the bolt force
Wm2
We have considered two conditions - Operating and Gasket
Seating

Wm1

Operating

Wm2

Gasket Seating

hG
hT
HD HT

hD

04/27/15

HP

HG
22

Forces produced by
pressure

Forces produced by bolt

tightening

Wm1

Operating

Wm2

Gasket Seating

hG
hT
HD HT

hD

04/27/15

HP

HG
23

In either case there is a Moment acting on the flange

Forces produced by
pressure

Forces produced by bolt

tightening

Wm1

Operating

Wm2

Gasket Seating

hG
hT
HD HT

hD

04/27/15

HP

HG
24

In either
Let
us now
case
investigate
there is athe
Moment
consequences
acting onof
the
Rotation
flange
Causing it to rotate about the bolt acting as a hinge

04/27/15

25

Let us now investigate the consequences of Rotation

The gasket is only squeezed at the outer edge
Squeezed over an effective width b
When the bolts are initially tightened we apply a
pressure y
Pressure y x effective gasket area gives us initial tightening
force
b

Thisforce
area is
This initial bolt tightening
is called HG
redundant

04/27/15

26

Let us now investigate the consequences of Rotation

The gasket is only squeezed at the outer edge
Squeezed over an effective width b
When the bolts are initially tightened we apply a
pressure y
Pressure y x effective gasket area gives us initial
tightening force
b

This initial bolt tightening force is called HG

04/27/15

27

We come back to the gasket later

Wm
1

Operatin
g

HD HT

HP
P

This initial bolt tightening force is called HG

When pressure is introduced, the squeeze on the gasket
relaxes

04/27/15

28

We come back to the gasket later

The
on stress
the flange
generates
three
This moment
is a typical
analysis
from PV
Elite stresses
SR Radial stress
ST Tangential (hoop)
stress

ST Hub (bending) stress

We need these three stresses for both the operating
and gasket seating (bolt tightening) conditions

04/27/15

29

Consider
rolegasket
of the later
Full Face gasket
We come now
backthe
to the
This is a typical stress analysis from PV Elite

In this case the analysis is per ASME VIII, Division 1

We need these three stresses for both the operating

and gasket seating (bolt tightening) conditions

04/27/15

30

Consider
This
whatnow
happens
the role
notice
of thecarefully
Full Face gasket
The gasket goes to the outside diameter of the
flange
Unless you know the leakage mechanism you are
doomed
The pressure causes these forces to act
The bolt tries to keep things together
But it may not be able to !

04/27/15

31

Thismust
We
whatunderstand
happens notice
the forces
carefully
acting on the flange
The flanges open up now there is a leakage path
Here it it..
Yes leakage occurs through the bolt holes !
How can we prevent this ?

04/27/15

32

We
Thismust
part understand
of the flanges
theacts
forces
as cantilever
acting on the flange
There are two forces acting upward pressure and balancing
forces
The bolt provides the other (equilibrium) force
Now take moments to get the bolt force
FB = FP . L
x
Increasing x reduces FB
This is important

04/27/15

FP

FB

FU

L
x

33

This GOLDEN
The
part of the
RULE:
flanges acts as cantilever
A shorter cantilever is more rigid (stronger)
We learn a very important lesson:
Increasing x lowers the bolt load
Increasing x makes for stronger flange
Flange lifting is decreased

FB

FB
x

04/27/15

34

The GOLDEN
This
is a typical
RULE:
rectangular flange
ALWAYS make x bigger then y
In other words: Keep the bolts closer to the inside
diameter of the flange
Let us consider the case of the rectangular flange
FB
y

04/27/15

35

Thisnow
We
is a study
typical
the
rectangular
gasket and
flange
its properties
Consider this cross, shown bigger here
section
Suppose the gasket is narrow, like
Here is the
this.
bolt
This side of the flange will twist like this
To solve this problem, you need a full face gasket

We have looked at the problems, now we look at the

gasket

04/27/15

36

Squeeze
We
now study
force the
andgasket
expansion
and can
its properties
be shown on a
graph
Suppose the gasket is perfectly elastic
In service the flanges move apart, for example when
pressurised
The gasket has expanded losing some of the squeeze off
loaded
There is a relationship between expansion and squeeze

Expansion

04/27/15

37

We can now
Squeeze
force
see
and
theexpansion
relationship
canbetween
be shown
the
ongasket
a
and
graph
bolts
This line represents the gasket squeeze versus
thickness
If the gasket expands (gets thicker), note what
happens
The gasket force is reduced
Bolt force versus bolt stretch can also be plotted on this
graph
As the bolt stretches, so the force to stretch increases

Forc
e

From here
To here

Gasket thickness expansion

Bolt stretch
04/27/15

38

First,
We
can
we
now
consider
see the
the
relationship
initial gasket
between
seating
the
- assembly
gasket and
bolts
First, we need the stiffness of the gasket and the bolts
KG = Stiffness of the gasket

lbf/in or N/mm

KB = Stiffness of the bolts

lbf/in or N/mm

Stiffness represents the slope (tangent) of the graph

e
lin
Bo
lt

Forc
e

Bolt
stretch

KB

Gasket
compressio
n
G
lin ask
e et

Increasing
force

KG

Stretch (bolt) or contraction

(gasket)
04/27/15

39

First, we consider the initial gasket seating - assembly

The entire bolt force is transferred to the gasket equilibrium
When pressure is introduced, the gasket is unloaded

Force from the bolt

= force on the
gasket

Tightening
force
Forc
e

KG

KB
Bolt
stretch

04/27/15

Gasket compression

40

This iswe
First,
the
consider
initial bolt
theforce
initialthat
gasket
wasseating
applied-at
assembly
the
beginning
The entire bolt force is transferred to the gasket equilibrium
When pressure is introduced, the gasket is unloaded
The gasket force is unloaded from , to here
here

Forc
e

KG

KB
Bolt
stretch

04/27/15

Gasket compression

41

Relationship
This
is the initial
between
bolt force
the stiffness
that wasofapplied
the bolt
atKthe
B and
beginning
Gasket KG
Residual force that is now on the gasket after pressure
introduced

Wm1 =
H+Hp

Forc
e

Hp
KG

KB
Bolt
stretch

04/27/15

Gasket compression

42

H
Relationship
between the stiffness of the bolt KB and
F
=
Gasket1KG KB
We set up these construction lines
KG
+
H = F +
Eliminating tg from the equations
y
= F + tg.KB
H
F =
F = tg.KG
KB
1
KG
+
y
H

Forc
e

tg
KG

KB
Bolt
stretch

04/27/15

Hp

Gasket compression

43

F =

ABK
.EBB.t
1
1
K
+ + GAG.EGG.
L stiffness in terms of E, Area and L
We need the

= E.e

= E
A x

(stress = elastic modulus x strain)

L
L
A
L

F
= E
L x

But

F
= K (the
L stiffness)

Finally:
F =
1
+
04/27/15

H
AB.EB.t
AG.EG.
L

44

H
Consider
the properties of the gasket
F
=
AB.EB.t
1
G
AG.EG.
+
L
FBO is known as the Initial Required Tightening Force
F is known as the gasket Off-Loading Compression
Force

Forc
e

KG

KB
Bolt
stretch

04/27/15

FBO

Gasket compression

45

Consider
Lets
go over
the properties
the problems
of the
causing
gasket
possible leakage
That straight line assumes the gasket obeys Hookes Law
True of all metal gaskets, but not for organic/synthetic
materials
This is how these other gasket materials squeeze and
release
That makes the analysis much more complicated

Force

g
Un
l

04/27/15

oa
d

Lo
a

di

in
g

compressio
n

46

Before
Lets
golooking
over the
at problems
the solution
causing
we consider
possible how
leakage
the Code
does it
As pressure increases, the gasket is unloaded
Tightening the bolts and adding pressure rotation
occurs
If one flange is hotter, the gasket is degraded
External moments and forces can release the gasket
The gasket generally does not obey Hookes Law

Force

g
Un
l

04/27/15

oa
d

Lo
a

di

in
g

compressio
n

47

Before
looking
at the
solution
we consider
thepsi/344
Code
The
fitter
actually
tightens
the bolts
to here how
(50000
does
MPa) it
We consider ASME Section VIII, Division 1 as an example
The code sets the initial bolt load about here (25 000 psi / 172
MPa)
After the pressure introduced the gasket relaxes to here
However, experience shows that the flange will leak
What is the solution ?

Forc
e

Wm2
Hp

KG

KB
Bolt
stretch

04/27/15

Gasket compression

48

The fitter
Dealing
with
actually
external
tightens
forcesthe
and
bolts
moments
to here (50000 psi/344
MPa)
The gasket now relaxes to here
Instead of here with the lower bolt load
That is the ONLY way the likelihood of leaks can be
prevented

Forc
e

FBOLT
Wm2

Hp

KG

KB
Bolt
stretch

04/27/15

Gasket compression

49

Dealing with external forces and moments

External
force

, and external moment

The force and moment are converted
into an equivalent pressure

04/27/15

50

Dealing
We
startwith
off with
external
the gasket
forces and moments
External
force

, and external moment

F
M

The force and moment are

converted into an equivalent
pressure
The conversion equation is known as
the Kellogg Equation for F and M
The derivation of this equation is
instructive

04/27/15

51

We start off with the gasket

For
b isthe
theMoment
effectiveMgasket
Start with
width
the section modulus of the
gasket Z
G is the effective gasket diameter
Force on the gasket from internal equivalent pressure Pe
F=

.G2.Pe
4

Thus the equivalent pressure from the external force

F is
4.F
Pe =
.G2
G

04/27/15

52

We start
The
final off
Kellogg
with the
equation
gasket
for the equivalent pressure is:
For the Moment M Start with the section modulus of the
gasket Z
.G2.b
Z=
4
Now we can find the stress S on the gasket from the
momentM
M
4M
=
S
.G2.
Z
=
The stress S frombthe equivalent pressure Pe
S
=

Force from Pe
Gasket area

0.25. .G2
=
.G.b

Equating the two equations for S we finally get Pe

16.M
Pe =
.G3
04/27/15

53

Standard
The
final Kellogg
flanges equation
such as B16.5
for the
and
equivalent
B16.47 can
pressure
be
is:
bought
4.F
16.M
+
Pe =
.G2
.G3
This is simply added to the design
pressure P
We have briefly discussed the design of flanges per
ASME
Our attention is now directed to standard flanges

04/27/15

54

Standard flanges such as B16.5 and B16.47 can be bought

This is what ASME Division 1 says about standard flanges
UG-11
The code does not require calculations for standard flanges

And in Table U-3 we get the standards referred to

04/27/15

55

Standard
The
flangeflanges
formulae
such
in as
ASME
B16.5
was
and
introduces
B16.47 can
in 1937
be bought
This is what ASME Division 1 says about standard flanges
UG-11
The code does not require calculations for standard flanges
If we analyse a standard flange, it can Why is
fail !
that ?
B16.5 did not come about by any analysis
It was the result is manufacturers forming a standard
under the auspices of the B16.5 committee many years
ago

04/27/15

56

The modern
flange formulae
approach
inis
ASME
by Finite
was introduces
Element analysis
in 1937
Do you remember this ?

A small number of flanges still suffer leakage

What attempts have been made to address this problem ?
04/27/15

57

The modern
Note
the meshing
approach
technique
is by Finite Element analysis
Companies such as Lannewehr & Thompson & Co KG have
written such software Flange Valid which considers all
the mechanical parameter that define a flange by kind
permission

The simulation of actual service condition can be analysed

using this method.
Here is a sample of the FEA models

04/27/15

58

Now come to the issue of assembling the flanges

Note the meshing technique

04/27/15

59

Here is such an apparatus

Now come to the issue of assembling the flanges
Personnel who assemble flanges need lots of experience
Welding personnel doing welding require to be qualified as
proof that they can produce defect free welds.
Responsible companies also qualify their flange assemblers
This can be done with a standard apparatus that can used
to allow fitters to demonstrate proficiency

04/27/15

60

Flanges still have to comply with code rules

Here is such an apparatus

04/27/15

61

Here is the PV Elite screen with everything you need

Flanges still have to comply with code rules
The calculations are very
However the computer.
tedious
PV Elite makes flange design very simple
All the dimensions can be entered in minutes to get
results
Changes can be made on the fly

04/27/15

62

Hereflange
The
is the required
PV Elite screen
thickness
with is
everything
instantly you
available
need

04/27/15

63

The can
You
flange
control
required
flange
thickness
rotationisto
instantly
code limits
available

04/27/15

64

You can add

control
an external
flange rotation
force and
to code
moment
limits

04/27/15

65

You can
This
has add
been
ana external
brief discussion
force and
onmoment
flanges

04/27/15

66

This has been a brief discussion on flanges

Thank you for your attention

Do you have any questions

04/27/15

67