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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
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2 up and 1
down
Bolt force
P
Pressure
force
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Gasket force
Bolt force
P
Pressure
force
Gasket force
Pressure force
8
Bolt force
P
Pressure
force
Gasket force
- Pressure
+
Pressureforce
force
9
Bolt force
P
Pressure
force
Gasket force
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
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
Pressure force
- Rotation
12
= Final Gasket
force
Tighte
n bolts
Force reduction from pressure
Gasket
force
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ForceResidual
reduction
orfrom
finalflange
gasketrotation
force
13
Gasket
force
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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
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mx
P
16
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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
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18
HD
HP
HT
HD HT
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HP
19
Wm1
HD HT
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HP
20
Wm1
hG
hT
HD HT
hD
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HP
21
Wm1
Operating
Wm2
Gasket Seating
hG
hT
HD HT
hD
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HP
HG
22
Forces produced by
pressure
Wm1
Operating
Wm2
Gasket Seating
hG
hT
HD HT
hD
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HP
HG
23
Wm1
Operating
Wm2
Gasket Seating
hG
hT
HD HT
hD
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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
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25
Thisforce
area is
This initial bolt tightening
is called HG
redundant
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Operatin
g
HD HT
HP
P
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Consider
rolegasket
of the later
Full Face gasket
We come now
backthe
to the
This is a typical stress analysis from PV Elite
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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 !
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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 ?
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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
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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
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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
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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
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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
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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
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
lbf/in or N/mm
e
lin
Bo
lt
Forc
e
Bolt
stretch
KB
Gasket
compressio
n
G
lin ask
e et
Increasing
force
KG
39
Tightening
force
Forc
e
KG
KB
Bolt
stretch
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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
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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
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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
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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
F
= E
L x
But
F
= K (the
L stiffness)
Finally:
F =
1
+
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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
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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
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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
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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
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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
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Gasket compression
49
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Dealing
We
startwith
off with
external
the gasket
forces and moments
External
force
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51
.G2.Pe
4
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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
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
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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
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56
The modern
flange formulae
approach
inis
ASME
by Finite
was introduces
Element analysis
in 1937
Do you remember this ?
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
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Hereflange
The
is the required
PV Elite screen
thickness
with is
everything
instantly you
available
need
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The can
You
flange
control
required
flange
thickness
rotationisto
instantly
code limits
available
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You can
This
has add
been
ana external
brief discussion
force and
onmoment
flanges
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