Proceedings of the ASME 2017 Pressure Vessels and Piping Conference

PVP2017
July 16-20, 2017, Waikoloa, Hawaii, USA

PVP2017-65439

DETERMINATION OF TARGET BOLT TENSION FOR FLANGES WITH LENS

GASKETS

Gys van Zyl

SABIC
Jubail, Saudi Arabia

ABSTRACT bolt loads on assembly and are sensitive to plastic deformation,

A lens gasket is a specific type of metallic ring gasket that is primarily as a result of over-torqueing, which may lead to the
usually only deployed in high pressure gas applications where a development of leaks.
high integrity bolted flange joint is required. Lens gaskets are not One of the operating plants had been experiencing recurring
common in ASME design and there are no ASME rules that issues with leaks from lens gasket flange joints. During the
guide the design of flanges with lens gaskets, nor are there course of investigating the primary cause of the leaks, it was
ASME standards to control lens gasket specifications. found that, in the absence of specific torque requirements, lens
Lens gaskets present a special challenge when determining gasket flanges had been assembled using torque tables meant for
target bolt tension values for flange assembly. For calculating standard gaskets (typically using a 50 ksi bolt stress). In a few
target bolt tension, the gasket seating width is an important instances noticeable plastic deformation of gaskets and seats
parameter. With lens gaskets, the gasket seating width depends were found at leaking flanges. Plastic deformation in one such
on the applied bolt tension, therefore calculation of bolt tension case where a flange was tensioned using a 50 ksi bolt load is
is by nature an iterative process. In these flange joints, the lens illustrated in Figure 1.
gasket has spherical machined surfaces that are in contact with
conical gasket seats in the flanges. At low bolt tensions, gasket
contact is nearly equivalent to line contact. At high bolt tensions,
finite contact widths are developed, sometimes involving plastic
deformation of the gasket.
This paper will present a method that was developed to
determine target bolt tension for a lens gasket bolted flange.
Reference will be made to European standards that address lens
gaskets, and the results of finite element analysis studies that
were used to validate the calculation method will be presented.
The successful deployment of the outcome of this work for all
the lens gasket flange joints on a plant will be discussed.

INTRODUCTION
At SABIC, lens gaskets are used for bolted flange (a) (b)
connections in certain high pressure gas services. It is most Figure 1 Comparing plastic deformation in a ring joint flange
commonly found in fertilizer plants (ammonia and urea) with with bolts tensioned to 50 ksi (a) and 15 ksi (b)
operating pressures that exceed 200 bar, and operating
temperatures around 200°C. In order to determine correct torque levels to use when
If correctly installed, lens gaskets have the advantage of assembling flanges, a validated calculation method was sought
generating a higher integrity seal than most competing designs, to determine bolt assembly target tension specifically for lens
as the gasket is, to a certain extent, self-energizing. However, gasket flanges.
lens gaskets are more difficult to install than, for example, ring
joint gaskets, and are more sensitive to imperfections on the
gasket seating surfaces. Lens gaskets require comparatively low

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 DESCRIPTION OF LENS GASKETS
A typical bolted flange joint using a lens gasket is illustrated
in Figure 2. The lens gasket has spherical faces that are seated
between two conical seating surfaces. This generates two lines
of contact between the gasket and seats upon initial assembly.
Once bolt loads are applied, deformation of gasket and seats will
generate narrow bands of surface contact between gasket and
seats.
INDUSTRY CODES AND STANDARDS RELATED TO
LENS GASKETS
There are no available ASME standards that address lens
gaskets, nor are lens gaskets considered in the flange design rules
of the ASME Boiler and Pressure Vessel Code [1].
Lens gaskets are specified in DIN 2696 [2]. This
specification provides tables with dimensional requirements for
lens gaskets for nominal flange sizes between 10 and 200 mm,
and pressure ratings between PN 62 and PN 400. The
specification does not limit materials, but provides for three
typical materials used to fabricate lens gaskets: carbon steel
(P245GH), 316Ti stainless steel (X6CrNiMoTi17-12-2) and 304
stainless steel (X6CrNiTi18-10). For design of flanges using lens
gaskets, DIN 2696 provides a calculation method to determine
gasket contact width and refers to AD 2000-Merkblatt [3] B7 and
B8 for the remaining aspects of the bolt load and flange design
calculation procedures.
The design of flanges that use lens gaskets are also covered
by EN 1591-1 [4]. This code provides a comprehensive design
methodology for bolted flange joints using a variety of gasket
types. A specific calculation procedure to determine gasket
contact width for lens gaskets is provided.

GENERAL APPROACH TO FLANGE BOLT LOAD

CALCULATION
The objective of the exercise is to calculate target bolt
tension values to use when assembling lens gasket flanges.
Figure 2 Bolted flange joint with lens gasket Furthermore, it was desired to have a calculation procedure that
follows the ASME BPVC flange design procedure as much as
Gasket dimensions that are relevant to the design of the bolted possible.
joint are illustrated in Figure 3. According to the flange design rules in ASME VIII
Division 1 Appendix 2 [1], the flange design bolt load is
determined from the required bolt loads for operating and
assembly conditions. The bolt load required for operating
conditions is determined from:
𝜋
𝑊𝑚1 = 𝐺 2 𝑃 + (2𝑏 × 𝜋𝐺𝑚𝑃)
4
𝑑𝐺2 This required bolt load is a function of the fluid pressure
𝜋
𝑑𝐺0 force ( 𝐺 2 𝑃) and the minimum gasket stress required for
𝑑𝐺1 4
adequate sealing (2𝑏 × 𝜋𝐺𝑚𝑃). Simply put, the latter
requirement means that the gasket stress must be 𝑚 times larger
𝑅 𝜑𝐺 than the internal pressure, where the 𝑚 factor depends on the
ℎ

type of gasket used. Note that the required bolt load is dependent
on the effective gasket seating width, 𝑏.

The bolt load for assembly is:

𝑊𝑚2 = 𝜋𝑏𝐺𝑦
The required bolt load ensures that the minimum required
gasket stress (𝑦) is generated on assembly. Parameter 𝑦 is
specific to the type of gasket used. Again, the required bolt load
is dependent on the effective gasket seating width.
For lens gaskets, the effective gasket seating width depends
on the magnitude of the applied bolt load. At very low loads,
Figure 3 Pertinent dimensions contact between the spherical surface of the gasket and the
conical seating surface will be a line. At a higher compressive
force, the gasket and seat will deform, leading to surface contact

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 between the gasket and seat. The width of the contact surface
will continue to increase as the compressive force is increased.
It is clear, therefore, that the required bolt load can only be
determined in an iterative manner, where bolt load influences
gasket seating width and vice versa.

CALCULATION OF GASKET SEATING WIDTH

The ASME BPVC provides no guidance on determination
of gasket seating width for lens gaskets, therefore other
calculation procedures were evaluated.
DIN 2696 expresses the gasket seating width using the
following equation:
3.5 𝑊𝑁 2.5
𝑏𝐷 = 0.58 √𝑅 ( )
𝑑𝐺0 𝜋𝑆𝑢

EN 1591-1 expresses the gasket seating width as: Figure 4 Typical finite element model
2
6𝑅 × cos(𝜑𝐺 ) × 𝑊 𝑊
𝑏𝐷 = √ +( ) The model used elastic perfectly plastic material properties
𝜋 × 𝑑𝐺0 × 𝐸𝐺 𝜋 × 𝑑𝐺0 × 𝑄𝑠𝑚𝑎𝑥
for the gasket and the seat. The following parameters could be
varied:
While the forms of the two equations are not the same, there  Contact diameter of gasket
are some similarities:  Spherical radius of gasket surface
 Both approaches use the force normal to the gasket  Yield strength of gasket material
seating surface (𝑊𝑁 and cos(𝜑𝐺 ) × 𝑊).
 Modulus of elasticity of gasket material
 Both approaches have consideration for the strength of
 Yield strength of seat material
the gasket material (𝑆𝑢 and 𝑄𝑠𝑚𝑎𝑥 ).
 Modulus of elasticity of seat material
However, only the EN 1591-1 approach has consideration
for the modulus of elasticity of the gasket material (𝐸𝐺 ).
A comparison between the different procedures to calculate
gasket contact width for a specific set of dimensional parameters
FINITE ELEMENT ANALYSIS OF LENS GASKET
is provided in Figure 5. The correlation between finite element
CONTACT WIDTH
analysis and the EN 1591-1 calculation method is good, except
In addition to the two code calculation procedures, a
for the final load step. The deviation at the final load step can be
parametric finite element model was developed to enable
attributed to large plastic deformation of the gasket. At the
estimation of the contact width for any combination of gasket
chosen dimensional, material, and load parameters, the final load
dimensions, materials and assembly force.
causes through section yielding of the gasket (see Figure 6).
A simplified axisymmetric model was created to represent
In the EN 1591-1 procedure, the maximum gasket surface
the typical state of contact between a lens gasket and a conical
pressure, 𝑄𝑠𝑚𝑎𝑥 , is one of the required variables. No guidance is
seat. Figure 4 illustrates the finite element model for a particular
provided in EN 1591-1 to select 𝑄𝑠𝑚𝑎𝑥 for solid metal gaskets.
set of dimensional parameters.
In this paper, 𝑄𝑠𝑚𝑎𝑥 was chosen as equal to the ultimate tensile
strength of the material, which resulted in the observed good
correlations.
Correlation between the DIN-2696 procedure and finite
element analysis is less good.

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 18
analyses. For this group, material properties for stainless steel
was used for both the gasket and gasket seat, gasket contact
Gasket contact width, mm

16 FEA
14 EN 1591-1 diameters varied between 15 and 600 mm, and 10°, 20° and 30°
12 DIN-2696 gasket seat angles were used. The plot shows good agreement
10
between the finite element analysis result and the gasket contact
8
width calculated using the EN 1591-1 procedure, but the
6
DIN 2696 method consistently over-predicts the gasket contact
4
width when compared to the finite element analysis results.
2 50
0
DIN 2696
0 500 1000 1500 2000 2500 3000 3500
EN 1591-1
Gasket force, kN
40

Calculated contact width, mm

Figure 5 Comparing DIN, EN and FEA calculation methods
for a specific gasket
30

(a)

20

10

0
0 10 20 30 40 50
FEA determined contact width, mm

Figure 7 Results of parametric study into determination of

gasket contact width

(b)
Figure 6 Plastic strain distribution in the gasket at the
second largest (a) and largest (b) loads in Figure 5
The better performance of the EN 1591-1 method compared
to DIN 2696 holds true in general. Figure 7 presents the results
of the parametric study that was done where gasket dimensions
were varied in approximately 150 different finite element
CALCULATION CONSIDERATIONS
Following the ASME calculation method, two bolt loads
have to be calculated: the operating load (𝑊𝑚1 ) and the assembly
load (𝑊𝑚2 ). In these calculations, two gasket parameters are
required: gasket seating stress, 𝑦, and gasket factor, 𝑚. Buchter
performed tests examining sealing with metal-to-metal contact
[5], and concluded that plastic deformation of the contact
surfaces is an essential requirement to create a reliable seal. He
also determined that the gasket “tightening factor” (analogous to
gasket factor 𝑚) ranges between 1.5 to 3.5, depending on joint
geometry, material and operating conditions.
EN-1591-1 [4] specifies a gasket factor 𝑚 equal 2.0 for solid
metal gaskets and a minimum required gasket surface pressure,
𝑄0𝑚𝑖𝑛 , consistent with the yield strength of the material (e.g.
250 MPa for stainless steel).
Based on the information from these references, the
following gasket parameters were selected:
𝑚 2.0
𝑦 yield strength of the gasket material
In practice, gasket stress exceeds the material yield strength
for any reasonable bolt load, as the gasket contact area is usually

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 small, starting off as line contact. Therefore, the requirement for Choose interim assembly load,
minimum gasket seating load (𝑊𝑚2 = 𝜋𝑏𝐺𝑦), is easily satisfied. 𝑊𝑖
Furthermore, in the typical applications where lens gaskets
are used (high internal pressures), the fluid pressure force
𝜋
( 𝐺 2 𝑃) is far greater than the minimum gasket stress required
4 Calculate gasket contact width:
for adequate sealing (2𝑏 × 𝜋𝐺𝑚𝑃), therefore the latter part of 2
this requirement is also easily satisfied. 6𝑅 × cos(𝜑𝐺 ) × 𝑊𝑖 𝑊𝑖
𝑏𝐷 = √ +( )
In many practical situations it was found that the minimum 𝜋 × 𝑑𝐺0 × 𝐸𝐺 𝜋 × 𝑑𝐺0 × 𝑆𝑢𝐺
requirements for operating and assembly loads could be reached
at fairly low bolt loads, which resulted in a very narrow gasket
contact width. For this reason, a requirement for the minimum
gasket contact width was added. AD Merkblatt B7 [3], has a
requirement for lens gaskets that the minimum contact width Check target contact
should be 2.0 mm. This requirement was adopted in the width: No
calculation procedure. 𝑅
𝑏𝐷 = max (2.0 𝑚𝑚, )
After numerous calculations and finite element analyses, it 50
was found that specifying a target gasket contact width as a
function of the gasket spherical radius resulted in very sensible
calculated bolt loads. A target contact width of 𝑏𝐷 = 𝑅/50 gave Yes
good results.
Because of the good correlation with finite element analysis
results, the procedure of EN 1591-1 was adopted to calculate
gasket contact width. Check gasket assembly No
stress:
𝑊𝑖 > 𝜋 × 𝑏𝐷 × 𝑑𝐺0 × 𝑦
CALCULATION PROCEDURE
To calculate the target bolt tension for assembly of a lens
gasket flange, an iterative procedure, as illustrated in Figure 8
was developed. Yes
In principle, the procedure follows the sequence:
 Choose a bolt load
 Calculate gasket contact width
 Iterate until the following conditions are met: Check gasket operating
o Achieve the target contact width stress: No
𝜋 2
o Achieve the minimum required assembly 𝑊𝑖 > 𝑑𝐺0 𝑃 + 𝜋𝑏𝐷 𝑑𝐺0 𝑚
stress 4
o Achieve the minimum required operating
stress
Yes

Target bolt load:

𝑊 = 𝑊𝑖

Figure 8 Flowchart for calculation of target bolt tension

CONCLUSION
The calculation method described above was used to
determine target torque values for all lens gasket pipe flanges on
a fertilizer plant. During a scheduled turnaround, approximately
25 flanges of various sizes were assembled successfully. One
flange had a minor leak during start-up, requiring an in-service
retorque. The plant has subsequently operated for seven months
without developing a flange leak.

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 NOMENCLATURE

𝑏 effective gasket seating width

𝑏𝐷 gasket contact width
𝑑𝐺0 gasket contact diameter
𝑑𝐺1 gasket inner diameter
𝑑𝐺2 gasket outer diameter
𝐸𝐺 modulus of elasticity of gasket material
𝐺 diameter at location of gasket load reaction
ℎ gasket thickness
𝑚 gasket factor
𝑃 internal pressure
𝑄𝑠𝑚𝑎𝑥 maximum gasket surface pressure
𝑅 gasket spherical radius
𝑊 flange assembly bolt load
𝑊𝑚1 bolt load required for operating conditions
𝑊𝑚2 bolt load required for assembly
𝑊𝑁 component of bolt load normal to gasket seat
𝑦 gasket unit seating load
𝜑𝐺 gasket seat angle

REFERENCES

[1] ASME Boiler and Pressure Vessel Code, Section VIII,

Division 1, New York: The American Society of
Mechanical Engineers, 2015.
[2] DIN 2696, Flange connections with lens shaped gasket,
DIN Deutsches Institut für Normung e. V., 1999.
[3] AD 2000-Merkblatt, Verband der TÜV e.V., 2010.
[4] BS EN 1591-1, Flanges and their joints - Design rules for
gasketed circular flange connections, London: British
Standards Instituion, 2013.
[5] H. H. Buchter, "Fundamental Principles for Static Sealing
with Metals in the High Pressure Field," in ASLE
Transactions, Chicago, 1973.

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