FLANGE LEAKAGE TEST AS PER

ASME BOILER & PRESSURE VESSEL CODE

Checking flanges for failure is one of the

most important activities of a stress engineer. It
is also considered as a complex activity because
of large amount of computation. In past few
decades flange test module is added in almost
all pipe stress programmes. However, there is
always
a
need
to
understand
the
procedure/calculations involved in stress
computations in flanges.
The flange test or selection is addressed in
various ASME codes. These codes are listed
below:
1. ASME BPVC Section VIII, Division 1
2. ASME BPVC Section VIII, Division 2
3. ASME BPVC Section VIII, Division 3
4. ASME BPVC Section I
5. ASME BPVC Section III
6. ASME B31.3 (Process Piping)
7. ASME B31.1 (Power Piping)
8. ASME B31.8 (Gas transmission lines)
9. ASME B31.4 (Liquid transmission lines)

parameters required for flange test. Flange test

for external loads is also added. At the end
different parameters as per ASME BPVC Section
VIII, Division 1, Appendix S are discussed.
Tables from ASME BPVC Section VIII, Division
1 are attached for ready reference.

Notations
A = outside diameter of flange, in. (mm)
Ab = cross-sectional area of the bolts using
the root diameter of the thread or least
diameter of unthreaded position, in2.
(mm2)
Am = total required cross-sectional area of
bolts, taken as the greater of Am1 and Am2,
in2 (mm2)
AP = area to outside of gasket contact, in2
Am1 = total cross-sectional area of bolts at root
of thread or section of least diameter
under stress, required for the operating
conditions, in2 (mm2)
Am2 = total cross-sectional area of bolts at root
of thread or section of least diameter
under stress, required for gasket seating,
in2 (mm2)
B = inside diameter of flange, in. (mm).
When B is less than 20g1, it will be optional
for the designer to substitute B1 for B in
the formula for longitudinal stress SH
b = effective gasket or joint-contact-surface
seating width in. (mm)
bo = basic gasket seating width (mm)
C = bolt-circle diameter, in. (mm)
D = nominal bolt diameter
d = factor, in3 (mm3)
E = modulus of elasticity for the material of
the flange at the design temperature
(operating condition) or atmospheric
temperature (gasket seating), as may
apply, psi
e = factor, in1 (mm1)
F = factor for integral type flanges
(see Table 2-7.2)
FA = applied force
Feq = equivalent axial force

Flange design in ASME BPVC Section VIII,

Division 1, is based on the design by formula
approach.
The allowable stresses used are as per ASME
B31.3 (Process Piping). It recommends
consideration of thermal insulation and external
loads in design.
In ASME BPVC Section VIII, Division 2, is based
on both design by formula and design by
analysis. It permit higher allowable then Section
VIII, Division 1.
ASME BPVC Section VIII, Division 3, is
generally used for design pressure greater than
10,000 psi.
ASME BPVC Section I, provides rules only for
flanges as per listed standards. No rules
provided for non standard flanges.
ASME BPVC Section III provides rules for
class1, 2 and 3 piping.
This write-up describes the procedure for flange
test as per ASME BPVC Section VIII, Division 1,
Appendix 2. The formulas shown are applicable
to only weld neck flange (integral type). A step
by step procedure is provided for stress
engineers to quickly recapitulate the different

FL = factor for loose type flanges (see Table 27.4)

f
= hub stress correction factor for integral
flanges (see Table 2-7.6)
G = diameter, in. (mm), at location of gasket
load reaction
go = thickness of hub at small end, in. (mm)
g1 = thickness of hub at back of flange, in.
(mm)
H = total hydrostatic end force, lb (kN)
HD = hydrostatic end force on area inside of
flange, lb (kN)
HG = gasket load (difference between flange
design bolt load and total hydrostatic end
force), lb (kN)
Hp = total joint-contact surface compression
load, lb (kN)
HT = difference between total hydrostatic end
force and the hydrostatic end force on area
inside of flange, lb (kN)
h = hub length, in. (mm)
hD = radial distance from the bolt circle, to
the circle on which HD acts, in. (mm)
(see Table 2-6)
hG = radial distance from gasket load
reaction to the bolt circle, in. (mm)
(see Table 2-6)
ho = factor, in. (mm)
hT = radial distance from the bolt circle to the
circle on which HT acts, in. (mm)
(see Table 2-6)
J = rigidity index <= 1.0
K = ratio of outside diameter of flange to
inside diameter of flange
KI = rigidity factor for integral- or optionaltype flanges
k = ratio of flange stiffness to gasket
stiffness
L = factor
M = moment
M0 = total moment acting upon the flange, for
the operating conditions or gasket seating
as may apply, in.-lb
ML = moment to produce flange leakage, in-lb
m = gasket factor (see Table 2-5.1)
N = width in mm, used to determine basic
gasket seating width bo
P = internal design pressure, psi (kPa)
Peq = equivalent pressure
S = nominal bolt stress
SH = calculated longitudinal stress in hub, psi
(kPa)
SR = calculated radial stress in flange, psi
(kPa)

ST = calculated tangential stress in flange,

psi (kPa)
Sa = allowable bolt stress at atmospheric
temperature, psi (kPa) (see ASME B31.3)
Sb = allowable bolt stress at design
temperature, psi (kPa) (see ASME B31.3)
Sf = allowable design stress for material of
flange at design temperature (operating
condition) or atmospheric temperature
(gasket seating), as may apply, psi (kPa)
Sn = allowable design stress for material of
nozzle neck, vessel or pipe wall, at design
temperature (operating condition) or
atmospheric temperature (gasket seating),
as may apply, psi (kPa)
T = factor involving K (see Table 2-7.1)
t = flange thickness, in. (mm)
U = factor involving K (see Table 2-7.1)
V = factor for integral type flanges
(see Table 2-7.3)
VL = factor for loose type flanges
(see Table 2-7.5)
W = flange design bolt load, for the operating
conditions or gasket seating, as may
apply, lb (kN)
Wm1= minimum required bolt load for the
operating conditions, lb (kN)
Wm2= minimum required bolt load for gasket
seating, lb (kN)
Y = factor involving K (see Table 2-7.1)
y = gasket or joint-contact-surface unit
seating load, psi (kPa) (see Table 2-5.1)
Z = factor involving K (see Table 2-7.1)

ASME Design method

(For Raised face and Ring-joint flange using ring
type gasket)
Following parameters are calculated as per
ASME design method:
1. Moment Arms
There are various forces that act on flange joint
(see Figure1). These forces when multiplied by
moment arm, creates moment in-turn twisting in
outward direction. Moment arms are tabulated
in Table 2-6 of ASME Section VIII, Division 1,
Appendix 2.
2. Effective gasket seating (b)
Effective gasket seating depends upon the
nominal gasket seating width. It is calculated
from Table 2-5.1. If also depends upon the type
of the gasket and gasket material.

For spiral-wounded metal gasket effective

gasket seating is calculated as:

Minimum required bolt load for operating case

(Wm1) = H + HP = 0.785 G2 P + (2b)(3.14 G m P)

N
, where
2
OD ID
N=
2
bo =

6. Required bolt area (Am)

Required bolt area for gasket seating (Am1)
Am1 =

If, bo <= 0.25 inch, then, b= bo

If, bo > 0.25 inch, then, b=0.5 b o

Required bolt area for operating case (Am2)

Am2 =

3. Gasket load reaction (G)

If, bo <= 0.25 inch, then, G= mean diameter of
gasket face
If, bo > 0.25 inch, then, G= outside diameter of
gasket contact 2b

Wm2
Sa

Am should be greater of Am1 or Am2

7. Flange moments
(For gasket seating case)
W= 0.5 (Am+ Ab) Sa
Mo = 0.5 W (C-G)

4. Forces
Forces acting on flange are classified as bolt
force, gasket force and hydrostatic end force.
These forces originate because of internal
pressure and gasket reaction force.
The schematic of flange joint indicating forces is
shown in Figure1.

(For operating case)

Mo = HD hD + HT hT + HG hG
hD, hT, hG = moment arms
for HD, HT, HG, see point 4.
8. Flange parameters
These parameters are based on the geometry of
the flange joint.
Parameters for all flanges:
a. Compute, K = A/B
b. Compute T
c. Compute U
d. Compute Y
e. Compute Z

HD

Wm1
Sb

HT

f. Compute

HG

g1 h
,
and ho
g o ho

where, ho =

Figure1. Forces acting on flange joint

Bbo)0.5

Parameters for integral type joint:

a. Compute F
b. Compute V
c. Compute f
d. Compute,

W = bolt force = 0.5 (Am+Ab) Sa

H= 0.785 G2 P
HG= gasket force = W-H
HD = hydrostatic end force = 0.785 B2 P
HT = H - HD

U
2
ho g o for integral type flanges
V
U
2
d=
ho g o for loose type flanges
VL
d=

5. Required bolt loads (Wm)

Bolt load is calculated in two cases. First case is
gasket seating case and other is operating case.
Gasket seating case is based on the gasket stress
at atmosphere temperature at initial start up, to
compress gasket to make a tight fit joint or seal.
Required bolt load for gasket seating and
operating case is calculated as given below:
Minimum required bolt load for gasket seating
(Wm2) = 3.14 b G y

e. Compute

F
for integral type flanges
ho
F
e = L for loose type flanges
ho
e=

f. Compute

7. Determine flange parameters K, T, U, Y,

te 1 t

T
d

L=

Z,

8. Compute parameters d, e and L

9. Calculate longitudinal hub stress (SH), radial
flange stress (SR) and tangential flange stress
(ST)
10. Compare with allowable values. Also check
combine cases

Flange Stresses
(Integral flanges and loose flanges with hubs)
Stress Types
1. Longitudinal hub stress (SH)

fM o

SH =

Flange Design for External Loads

1. Bolt Stress Limits
The maximum external moment to avoid
leakage is given by the formula below:

Lg1 B

2. Radial flange stress (SR)

SR =

(1.33te 1) M o
Lt 2 B

C
(Sb Ab P AP)
4

ML =

3. Tangential flange stress (ST)

ST =

g1 h
,
, F, V and f
g o ho

2. The equivalent pressure method

Equivalent pressure is computed as the pressure
that gives the same maximum
longitudinal stress in flange neck as the applied
force.

YM o
ZS R
t2B

Allowable values
SH < 1.5 Sf and 2.5 Sn
ST < Sf
SR < Sf

Peq =

16
4
M
FA
3
G
G 2

This equivalent pressure is added to the design

pressure and then total pressure
is determined by either one of the following:
a. Comparison with ANSI B16.5 flange rating
b. Computation in accordance with ASME Sec
VIII design rules

Combine case

SH SR
< Sf
2
S H ST
< Sf
2

3. Equivalent axial force method

a. Compute maximum axial stress in flange neck
that results from bending and axial forces.
b. Flange is analyzed using ASME procedure
and adding an axial symmetric force equivalent
to maximum longitudinal stress. Moments can
be converted into an equivalent axial force on
the basis of the gasket diameter.

Step by step procedure for flange test

1. Find m and y from Table 2-5-1 of Section
VIII Division 1, Appendix 2. (Also see
manufactures catalogue for details)
2. Find code allowable stress values, Sa , Sb , Sf
and Sn
3. Compute gasket reaction location (bo) and
effective width (G)
4. Compute required bolt loads i.e. y, Wm2, Wm1,
H, HP, HD, HT
5. Compute required bolt area, Am1 and Am2
6. Compute flange moments at gasket seating
and operating condition i.e. Mo

Feq =

4M
G

4. Gasket Reaction
This approach looks into gasket reaction force
alone
5. FEA
A detail finite element analysis is done

ASME Section VIII, Division 1, Appendix S:

Design Consideration for Bolted Flange
Connections
ASME Section VIII, Division 1, Appendix S,
discuss the design considerations of flange
assembly, bolt stresses and flange rigidity.
1. Bolted stress for manually tightened bolts
S=

45000
D

2. Flange rigidity factor (J)

(For integral type Flanges)
J=

52.14M oV
2

LEg o ho K I

where, KI = 0.3 (for integral type flanges)

J should be less than or equal to 1.0. If greater
than 1.0 flange thickness should
be increased
3. Bolt spacing
Bolt spacing (max) =

2d 6t
m 0.5

Or
Bolt spacing = t 4 k

Reference
1. ASME BPVC, Section VIII, Division1,
Appendix 2
2. ASME BPVC, Section VIII, Division1,
Appendix S
3. Companion Guide to ASME Boiler & Pressure
Vessel Code, Second Edition, Volume- 2

Appendix

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