INTERNATIONAL JOURNAL FOR RESEARCH IN EMERGING SCIENCE AND TECHNOLOGY, VOLUME-2, ISSUE-7, JULY-2015 E-ISSN: 2349-7610

Design and Analysis of Oval Shape Flange for Chiller

Dinesh M. Ugle1 and Dr. M.J. Sheikh2

1
M. Tech Research Scholar, B.D.C.E. Sevagram, India
1
dinesh_ugle2009@rediffmail.com
2
Assoc. Professor, Mechanical Dept. B.D.C.E. Sevagram, India
2
mjsheikh_1971@rediffmail.com

ABSTRACT
Flange joints are very common in pressure vessel and piping systems. Flanges are primarily used where a connecting or
dismantling joint is needed. These joints may include joining pipe to fittings, valves, equipment, or any other integral component
within the piping system. The performance of joint is characterized mainly by its strength and sealing capability. However,
recommended design procedures for bolted flange joints are available in international codes and standards. In this paper, bolted
flange connections are analyzed by implementing the design method of ASME Boiler and Pressure Vessel Code. The results of a
parametric study of the behavior of flanges and stresses in bolts are analyzed by varying the flange thickness, bolt preload and
number of bolts, at the same time maintaining other flange dimensions constant. Theoretical results obtained using ASME design
approach is compared.

Keywords— Stresses, Asme Code, Flange.

1. INTRODUCTION Coefficient of performance. Ammonia as a refrigerant has zero

Chillers find applications in industries like: chemicals, global warming potential and therefore these absorption

pharmaceuticals, dairies, ice production, food and beverage machines, like Lithium bromide machines, are based on an

processing and cold storages. industrial chillers are used for eco-friendly technology.

controlled cooling of products, mechanisms and factory

Chiller is a device that removes heat from liquid. This liquid
machinery. Industrial chillers are also used in the plastic
(Lithium Bomider) can be used in heat exchanger to cool air or
industry in injection and blow molding, metal working cutting
equipment as per requirement. This investigation involves the
oils, welding equipment, die-casting and machine tooling.
use of finite element analysis (F.E.A) to predict levels of stress
They are also used to cool high-heat specialized items such as
and deflection of a particular flanged joint In this project tube
MRI machines and lasers, and in hospitals, hotels and
side of equipment is oval shape, for designing this ASME
campuses.
SEC. VIII DIV.2 is preferred, instead of ASME SEC. VIII

Important specifications to consider when searching for DIV. 1, Because this division is restricted over circular shape

industrial chillers include the total life cycle cost, the power only. But, because of ASME SEC. VIII DIV. 2 division is

source, chiller IP rating, chiller cooling capacity, evaporator expensive. The study of flange using FEA analysis. After

capacity, evaporator material, evaporator type, condenser design compare the results with ASME allowable limit.

material, condenser capacity, ambient temperature, motor fan

type, noise level, internal piping materials, number of 2. PROBLEM DEFINITION
compressors, type of compressor, number of fridge circuits, HTG (High Temperature Generator) channel shell, tubesheet,
coolant requirements, fluid discharge temperature, and body flange and cover flange cannot be calculated to the rules

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INTERNATIONAL JOURNAL FOR RESEARCH IN EMERGING SCIENCE AND TECHNOLOGY, VOLUME-2, ISSUE-7, JULY-2015 E-ISSN: 2349-7610

of ASME Section VIII-1 due to the complexity of the shape.
Hence the guidelines of the ASME Section VIII-2 are used
with the allowable stress limits of ASME Section VIII-1 and
Finite Element Analysis (FEA) is done to meet the
requirement of ASME Section VIII-2.
• Modeling will be via linear static analysis.
• Stud loads will be averaged over the area where the
studs are located in the circular ring.
3.2 Design Parameter

Specific objectives relating to this project include: The input parameter we are considering for the design and

 Research background information relating to the analysis of Oval shape flange are as per the company standards

assembly stresses produced when bolting two flanges and customer specification.
together.
Tube side design pressure=1.054 MPa
 Construction of parametric model finite element
analysis techniques. Design Temperature=300 °C
 Analysis of output from finite element analysis
Tube Side Mean metal temperature=150 °C
model.
 Stress linearization of stress concentrated areas. Shell Side Mean metal temperature=135 °C
 Calculation of Membrane, Bending & peak stresses
Minimum Design Metal Temperature=-10 °C
along the thickness of highly stress concentrated
zone.
 Compare above stresses with the allowable limit
given by ASME. 3.3 Model Information

HTG consisting of tubesheet with tube holes, cover plate,

Research Methodology relating to this project include:
nozzle with end cap, channel shell and main shell is modeled.
 Study of sources of failure of Oval Shape flange.
The main shell is not the part of the analysis; they are modeled
 Identification of Critical design parameters.
to transfer the forces.
 Design of Oval shape flange.
Parametric model are used to design a model, having similar
 Construction of Parametric Model using SOLID
geometry but different dimensions.
WORK.
3.4 Material of Construction
 FEM analysis using SOLID WORK.
The following material properties are extracted from

3. DESIGN OF OVAL SHAPE FLANGE ASME Section II Part D.

3.1 Basic Assumptions 1) Channel Shell / Main Shell / Tubesheet / channel flange/
cover flange
In order to simplify the analysis of the flanged joint, a
number of assumptions were made. These assumptions are Table-I Flange Material

made to avoid the complexity of the problem, In a such

Description
way that it will not affect the final result.

Select the Material= SA-516 Gr 70

These basic assumptions are:

• All materials for the model, blind, gasket and hub Design Temperature=200°C

flange are assumed isotropic, i.e. materials have the

Nominal Composition= Carbon steel
same elastic properties in all directions, which is a
valid approximation for steel.
• Considering self-energizing gasket.

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Product Form=plate (2b*3.14*G+2*b*2*SP)m*P………………(2)

Wm2 = (3.14*b*G+2*SP*b)*y………………. (3)
Size / Thickness--- Where,
‘b’ is the effective gasket seating width [mm];
UNS No.= K02700
‘G’ is the diameter at location of gasket force [mm];
‘y’ is the gasket seating stress [mm];
P. No.=1
‘P’ is the calculation pressure [MPa] and
Group No.=2 ‘m’ is a gasket factor.
The total cross-sectional area of bolts Am required for both the
Min. Tensile Strength=485 MPa operating conditions and gasket seating is the greater of the
values for Am1 and Am2,
Min. Yield Strength=260 MPa
Am1 = Wm1/Sb…………………………………. (4)
External pressure Chart No.=CS-2 Am2 = Wm2/Sa…………………………………. (5)
Am = Max(Am1,Am2) Available Cross-sectional area
Density=7750 kg/m3
of the Bolts,
Ab = pi/4*db2*nb……………………………… (6)
Maximum Allowable Stress=136 MPa
A selection of bolts to be used shall be made such
Yield Stress=204 MPa that the actual total cross-sectional area of bolts Ab will not
be less than Am.
Ultimate Tensile Strength=483 MPa Flange design bolt load,
For operating condition W [N],
Modulus of Elasticity=1850 MPa
W = Wm1……………………………………… (7)

Mean Coefficient of Thermal Expansion=1.330E-05

For gasket seating condition,
Wg = (Am + Ab)*Sa/2……………………………. (8)
Poisson's Ratio=0.3

3.5 Design Procedure

The target load bolt-up method was used to calculate target

bolt-up forces and subsequent flange stresses.

3.6 ASME Flange Design Bolt Forces

As per ASME Mandatory Appendix II, the following section Fig.1 Integral Flange Detail

details the procedure required to calculate the minimum

4. FINITE ELEMENT ANALYSIS
required bolt force for a flanged joint.
4.1 General Remarks
The maximum of the two calculated forces , Wm1 and
Finite Element Method, popularly known as FEM, involves
Wm2 is used to set the minimum required bolt force as
analysis of the entire structure, instead of separately
set out below.
considering individual elements with simplified or assumed
Wm1 = H + Hp…………………. (1) end conditions. It thus helps in· a more accurate estimate of
the stresses in the members, facilitating optimum design. FEM
Wm1 = (0.785G2+G*SP)*P+
involves idealizing the given component into a finite number
of small elements, connected at nodes. FEM is an extension of

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Rayleigh-Ritz method, eliminating the difficulty of dealing 4.3 Pressure

with a large polynomial representing a suitable displacement
Internal pressure of 1.054 MPa is applied all over the channel
field valid over the entire structure. Over each finite element,
area including the channel flange, tubesheet & nozzle.
the physical process is approximated by functions of desired
type and algebraic equations, which relate physical quantities
at these nodes and are developed using variational approach.
Assembling these element relationships in the ·proper way is
assumed to approximately represent relationships of physical
quantities of the entire structure.

4.2 Constrains for shell flange

The Tube sheet, bolt & back side of shell is constrained in

all the directions as shown in figure given below.

Fig. 5 Tube Side Pressure

Vacuum is applied over the shell and shell side of the

tubesheet

Fig. 2 Tube sheet constrain

Fig. 6 Shell Side Pressure

Table-II Flange mesh detail and check

Mesh type Mesh Using Solid Elements

Standard mesh using

Fig.3 Bolt constrain Mesh Used parabolic

tetrahedral solid elements

defined by four corner
nodes, six mid side nodes
and six edges

Element size 45 mm

Mesh quality High

Total nodes 81651

Total elements 42025

Fig.4 Shell Constrain

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Fig.08 Stress Plot

Fig. 07 Mesh Convergence

4.5 Mesh convergence

For the optimum selection of the mesh size and

plotting of the results, deflection convergence is
established and the percentage variation is kept
under 10%. Details are as follows –
Fig.09 Displacement Plot

Table-III Mesh Check for Shell Flange

Table-04 Stress Comparison
Maximum
Von Mises Manually %
Description Mesh Nodes Elements Deflection Software output
stress calculated Error
mm
Membrane
Plot Run 45 81651 42025 0.1038 27.11 MPa 26.57 MPa 2.03
Stress

Check Run 35 92167 47700 0.1125

Bending Stress 103.63 MPa 106.40 MPa 2.60

Percentage
- - - 8.38 %
Varation
As the maximum variation of stresses less than 10%,
Convergence is achieved. Now the final stage i.e. checking

As the maximum variation in less than 10% the with allowable limit. As the stresses obtain is less then

convergence is achieved and the results will be plotted with allowable value of stresses as per ASME Section VIII-2 and

the mesh size 45 (Plot Run). allowable stress limit allowed for ASME Section VIII-1.

4.6 Result
5. CONCLUSIONS
Stress Plot give stresses at various portion. Color represent Bolted flange connections are analyzed by implementing the
intensity of stress variation. design method for gasketed bolted flanged connections as per
ASME Boiler and Pressure Vessel Code and results were
validated with finite element analysis results. It is concluded
from this investigation that the maximum stresses developed
on flange are at middle part of the bolt and it is within the

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acceptable limit specifying by ASME. Firstly, mesh [6] Bouzid A, Nechache A. Thermally induced deflections
convergence is done using deflection analysis, as maximum in bolted flanged connections. ASME J Pressure Vessel
deformation in both the analysis is less than 10% hence, Technol 2005;127: 394–401.
convergence is achieved. [7] Dennis R. Moss, (1997), Pressure Vessel Design
Manual, Second Edition, Gulf Publishing Company,
From the Finite element analysis the maximum stresses are
Houston, Texas, pp. 141-56.
reported in shell flange of 5N model, but the stresses are
[8] ASME Section VIII Division 1, (2013), Alternative
within acceptable limit specified by ASME. The lowest values
Rules for Construction of Pressure Vessels, Two Park
of stresses are reported in 2K model. Stress results obtained
Avenue, New York.
from the F.E.A. analysis indicated the flanged joint is within
[9] ASME Section VIII Division 2, (2013), Alternative
acceptable levels. It was attempted to compare the F.E.A.
Rules for Construction of Pressure Vessels, Two Park
results with that of the target load bolt-up method. Stress
Avenue, New York.
results obtained from the F.E.A. analysis indicated the flanged
[10] ASCE Standard, (2010), Minimum Design Loads for
joint is within acceptable levels. It was attempt to compare
Buildings and Other Structures, 1801 Alexander Bell
F.E.A. result with the stresses obtain as a output from stress
Drive, Reston, Virginia.
linearization method. Result gave output stresses within the
[11] IS 875 - Part 3, (1987), Code of Practice for Design
acceptable limit specify by ASME.
Loads (Other Than Earthquake) For Buildings And
Structures – Wind Loads, New Delhi.
REFERENCES [12] UBC Volume 2, (1997), Structural Engineering Design
[1] Hichem Galai and Abdel-Hakim Bouzid," Analytical Provisions, California.
modeling of flat face flanges with metal-to-metal contact [13] IS 1893 - Part 1, (2002), Criteria for Earthquake
beyond the bolt circle, "Journal of Pressure Vessel Resistant Design of Structures - General Provisions and
Technology, vol. 132, pp. (061207)1-8, 2010. Buildings, New Delhi.
[2] Murali Krishna, M. Finite element analysis and [14] IS 1893 - Part 4, (2005), Criteria for Earthquake
optimization of bolted flange joints with gasket, MS Resistant Design of Structures - Industrial Structures
thesis, Indian Institute of Technology Madras, 2005. Including Stack-Like Structures, New Delhi.
[3] Koji Kondo, Yuya Omiya, Takashi Kobayashi, and [15] Lloyd E Brownell & Edwin H Young, (1991), Process
Toshiyuki Sawa, "Scatter of bolt pre loads in pipe loads Equipment Design, Sixth Wiley Eastern Reprint, John
in pipe flange connection tightened by impact wrench Wiley & Sons, Inc., New York, pp. 203-18.
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[4] Mathan G and Siva Prasad N, "Studies on gasketed
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