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Flanges: Design & Problems

Presenter: Ray Delaforce

5/17/2017 1
 Flanges: design and problems

5/17/2017 2
 Here is a typical flange installation

5/17/2017 3
 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

5/17/2017 4
 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

Clearly leakage is a serious problem for industry

So, logically, we should start with the reasons why leakage occurs

5/17/2017 5
 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

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 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

5/17/2017 7
 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

5/17/2017 8
 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

5/17/2017 9
 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

5/17/2017 10
 We look at some of the reasons why leakage occurs

The bolt supplies the squeeze on the gasket

Internal pressure gives rise to a separating force

There are now 3 forces acting on the flange 2 up and 1 down

Bolt force

P
Pressure
force
Gasket force

5/17/2017 11
 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 + Pressure force

5/17/2017 12
 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:
Gasket force = Bolt force - Pressure force

5/17/2017 13
 We look at some of the reasons why leakage occurs

If the Bolt force = Pressure force : No Gasket squeeze occurs

The flange releases the gasket leakage occurs !

Bolt force

P
Pressure
force
Gasket force
Turning this equation around:
Gasket force = Bolt force - Pressure force

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 We look at some of the reasons why leakage occurs

Let us look more closely at the gasket between the flanges

The bolts act as a hinge flanges rotate from bolt and pressure forces

Gasket force = Bolt force - Pressure force

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 We look at some of the reasons why leakage occurs

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 - Pressure force

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 The equation is adjusted to take into 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 - Pressure force - Rotation

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 Let us consider the residual gasket squeeze

Bolt force - Pressure force - Rotation of the flange = Final Gasket force

Tighten Remember, there is no pressure at this stage

bolts

Force reduction from pressure

Force reduction from flange rotation

Gasket
force

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 Let us consider the residual gasket squeeze

Bolt force - Pressure force - Rotation of the flange = Final Gasket force

What should this residual force be ?

Tighten
bolts

Residual or final gasket force

Gasket
force

Residual = After pressure, after rotation

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 Let us consider the residual gasket squeeze

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 squeeze on the gasket is less than fluid pressure - leakage

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 Let us consider the residual gasket squeeze

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

mxP
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 So far we have considered Mechanical problems with leakage
The difficult problems are thermal in nature
Consider what happens when one flange is hotter than the other

It walks over the gasket causing it to degrade

5/17/2017 22
 So far we have considered Mechanical problems with leakage
The difficult problems are thermal in nature
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

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 So far we have considered Mechanical problems with leakage
Consider another mechanical problem an external moment

Flange rotation can occur

5/17/2017 24
 So far we have considered Mechanical problems with leakage
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

5/17/2017 25
 So far we have considered Mechanical problems with leakage
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

5/17/2017 26
 We now consider the forces acting on the flange under pressure

Force inside the bore from pressure HD

Residual force to squeeze the gasket HP
Force on the annular space HT

These forces are balanced by the bolt for Wm1

Wm1

HD HT HP
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 We now consider the forces acting on the flange under pressure

Thus Wm1 = HD + HP + HT
Wm1 is the OPERATING bolt force

Wm1

HD HT HP
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 We now consider the forces acting on the flange under pressure
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
HD HT HP
5/17/2017 29
 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 Wm2

Operating Gasket Seating

hG
hT
hD
HD HT HP HG
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 Wm1 Wm2

Operating Gasket Seating

hG
hT
hD
HD HT HP HG
5/17/2017 31
 In either case there is a Moment acting on the flange

Forces produced by pressure Forces produced by bolt tightening

Wm1 Wm2

Operating Gasket Seating

hG
hG
hT
hD
HD HT HP HG
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 In either case there is a Moment acting on the flange
Causing it to rotate about the bolt acting as a hinge

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 In either case there is a Moment acting on the flange
Causing it to rotate about the bolt acting as a hinge

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 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

This is the initial bolt force Hg

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 HG
b

This initial bolt tightening force is called HG

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 Wm
1

Operating

HD HT HP b

This initial bolt tightening force is called HG

When pressure is introduced, the squeeze on the gasket relaxes

5/17/2017 And the squeeze relaxes to Hp 37
 We come back to the gasket later

The moment on the flange generates three 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

5/17/2017 38
 We come back to the gasket later

This is a typical stress analysis from PV Elite & CAESAR II

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

5/17/2017 39
 Consider now the role of the 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 !

5/17/2017 40
 This what happens notice carefully , a prying action !
The flanges open up now there is a leakage path

Here it is..

Yes leakage occurs through the bolt holes !

How can we prevent this ?

5/17/2017 41
 We must understand the forces 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
FP FB FU
Increasing x reduces FB
L
This is important x

Moments
About
here

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 This part of the flanges acts as cantilever

A shorter cantilever is more rigid (stronger)

FB

5/17/2017 43
 This part of the 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

5/17/2017 44
 The GOLDEN RULE:

ALWAYS make x bigger than 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 x

5/17/2017 45
 This is a typical rectangular flange

Consider this cross-section , shown bigger here

Suppose the gasket is narrow, like this. Here is the bolt

This side of the flange will twist like this

5/17/2017 46
 This is a typical rectangular flange

Consider this cross-section , shown bigger here

Suppose the gasket is narrow, like this. Here is the bolt

This side of the flange will twist like this

To solve this problem, you need a full face gasket

5/17/2017 47
 This is a typical rectangular flange

Consider this cross-section , shown bigger here

Suppose the gasket is narrow, like this. Here is the 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 consider the gasket

5/17/2017 48
 We now study the gasket and its properties
Suppose the gasket is perfectly elastic
In service the flanges move apart, for example when pressurised

5/17/2017 49
 We now study the gasket and its properties
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

5/17/2017 50
 Squeeze force and expansion can be shown on a graph

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

Force From here

To here

Gasket thickness expansion

Forward
Bolt stretch
5/17/2017 51
 We can now see the relationship between the 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 lines

Bolt Gasket
stretch compression
Force
Increasing
force

KB KG

Stretch or contraction

We can work out bolt stretch to gasket squeeze but not here
5/17/2017 52
 We are ready to investigate relationship between gasket and bolt
Start off with what happens with the residual gasket force HP
Apply an extra force gasket not compressed any further F

Force

Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 53
 We are ready to investigate relationship between gasket and bolt
Start off with what happens with the residual gasket force HP
Apply an extra force gasket not compressed any further F
Because we have already applied the pressure force H

However, bolt force

increases

Force
F

Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 54
 We can calculate F in terms of y, tG and H
Start off with what happens with the residual gasket force HP
Apply an extra force gasket not compressed any further F
Because we have already applied the pressure force H

However, bolt force

increases

H
Force
F

Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 55
 We can calculate F in terms of y, tG and H
H = F + y
= F + tG.KB (from similar triangles)
F = tG.KG

Eliminating tG from the equation

Y
H
Force
F

tG Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 56
 We can calculate F in terms of y, tG and H
H y
H = F +
KB
1+
KG

Eliminating tG from the equation

H
F =
KB
1+
KG

5/17/2017 57
 Equation in terms of the Elasticity of the bolt and gasket
H
F =
KB
1
1+ +
KG

Converting stiffness into Elasticity and stretch, generally:

Elastic Modulus x Component Area E.A

K= =
Original Length L
Finally:

H
F =
AB.EB.tG
1+
AG.EG.L

5/17/2017 58
 Setting out the terms used in the equation:
H
F =
AB.EB.tG
1+
AG.EG.L

H = Force from internal pressure

AB = Total area of the bolts

EB = Elastic Modulus of the bolts
L = Length of the bolts
AG = Area of the gasket (effective area)

EG = Elastic Modulus of the gasket

tG = Thickness of the gasket

5/17/2017 59
 Setting out the terms used in the equation:
H
F = F is the gasket relaxing force (off loading)
AB.EB.tG
1+
AG.EG.L

When F reaches H, the gasket is reduced to its residual stated

H
Force
F

Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 60
 Consider the properties of the gasket

That straight line assumes the gasket obeys Hookes Law

True of all metal gaskets, but not for organic/synthetic materials

This is how these materials squeeze and release

H
Force
F

Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 61
 Consider the properties of the gasket

We have assumed the gasket obeys Hookes law

True of all metal gaskets, but not for organic/synthetic materials

Force

compression

5/17/2017 62
 Consider the properties of the gasket

We have assumed the gasket obeys Hooke law

True of all metal gaskets, but not for organic/synthetic materials

This is really how these materials squeeze and release

That makes the analysis much more complicated

Force

compression

5/17/2017 63
 Lets go over the problems causing possible leakage

As pressure increases, the gasket is unloaded

5/17/2017 64
 Lets go over the problems causing possible leakage

As pressure increases, the gasket is unloaded

Tightening the bolts and adding pressure rotation occurs

5/17/2017 65
 Lets go over the problems causing possible leakage

As pressure increases, the gasket is unloaded

Tightening the bolts and adding pressure rotation occurs
If one flange is hotter, the gasket is degraded

5/17/2017 66
 Lets go over the problems causing possible leakage

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

5/17/2017 67
 Lets go over the problems causing possible leakage

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

compression

5/17/2017 68
 Before looking at the solution we consider how the Code does 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 ?

H
Force
F
Wm2

Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 69
 Dealing with external forces and moments

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

H FBOLT
Force
F
Wm2

Hp

KB KG

Bolt stretch Gasket compression

5/17/2017 70
 Dealing with external forces and moments

External force , and external moment

5/17/2017 71
 Dealing with external forces and moments

External force , and external moment

The force and moment are converted into

an equivalent pressure

5/17/2017 72
 Dealing with external forces and moments

External force , and external moment

F The force and moment are converted into

an equivalent pressure
M
The conversion equation is known as the
Kellogg Equation for F and M

The derivation of this equation is

instructive

5/17/2017 73
 We start off with the gasket

b is the effective gasket width

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
Force over the area within G
G b

5/17/2017 74
 We start off with the gasket

For the Moment M Start with the section modulus of the gasket Z

Z= .G2.b I do not give the proof here

4
Now we can find the stress S on the gasket from the moment M
M 4M
S= =
Z .G2.b
The stress S from the equivalent pressure Pe
Force from Pe
= Pe.0,25. .G
2
S=
Gasket area .G.b
Equating the two equations for S we finally get Pe
G b
16.M
Pe =
.G3

5/17/2017 75
 The final Kellogg equation for the equivalent pressure is:

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

5/17/2017 76
 Standard flanges such as B16.5 and B16.47 can be bought
This is what ASME Division 1 says about standard flanges UG-11

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

5/17/2017 77
 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
If we analyse a standard flange, it can fail ! Why is 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

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 The flange formulae in ASME was introduces in 1937
Do you remember this ?

A small number of flanges still suffer leakage

What attempts have been made to address this problem ?

5/17/2017 79
 The modern approach 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

5/17/2017 80
 Note the meshing technique

5/17/2017 81
 Now comes 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

5/17/2017 82
 Here is such an apparatus

5/17/2017 83
 Custom flanges still have to comply with code rules

The calculations are very tedious However the computer.

PV Elite & CAESAR II makes flange design very simple

All the dimensions can be entered in minutes to get results

Changes can be made on the fly

5/17/2017 84
 Here is the PV Elite screen with everything you need

5/17/2017 85
 The flange required thickness is instantly available

5/17/2017 86
 You can control flange rotation to code limits

5/17/2017 87
 You can add an external force and moment

5/17/2017 88
 This has been a brief discussion on flanges

5/17/2017 89