235728132-Flange-Leakage.pdf

L&T Engineering , Faridabad

GUIDELINES FOR FLANGE LEAKAGE CALCULATION

Document No PD-DP-0005

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TABLE OF CONTENTS

1 2 3 4 5

SCOPE ........................................................................................................................ 3 CODES / STANDARDS............................................................................................... 3 WORK PROCEDURE FOR CAESAR ......................................................................... 3 WORK PROCEDURE FOR AUTOPIPE. ................................................................... 18 REFERENCE DOCUMENTS .................................................................................... 48

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server. © L&T- DEC 2005. Contains confidential confidential and/or proprietary information information to L&T and its its affiliated companies companies which shall not be used, disclosed or reproduced in any format format by any non-L&T party without L&T’s prior written permission. permission. All rights reserved. Format EN-FT-4061, Rev 0




Rev 0A

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TABLE OF CONTENTS

1 2 3 4 5

SCOPE ........................................................................................................................ 3 CODES / STANDARDS............................................................................................... 3 WORK PROCEDURE FOR CAESAR ......................................................................... 3 WORK PROCEDURE FOR AUTOPIPE. ................................................................... 18 REFERENCE DOCUMENTS .................................................................................... 48




GUIDELINES FOR FLANGE LEAKAGE CALCULATION 1

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SCOPE This document states the guidelines to perform flange leakage calculation on CAESAR II and Auto Pipe V8i.

2

3

CODES / STANDARDS ANSI B16.5

Pipe flanges and flanged fittings .

ASME B16.47

Large diameter steel flanges .

ASME Sec. VIII Div.1&2

Rules for construction of pressure vessels.

ASME B 16.20

Metallic gaskets for pipe flanges.

ASME Sec. II, Part D

Properties of materials.

ASME B31.3

Process piping.

WORK PROCEDURE FOR CAESAR The procedure for calculation shall be explained through a sample calculation. Flange size

: 10”

Flange Rating

: 900#

Gasket type

: RTJ-octagonal, RTJ-octagonal, B16.20 Cl.900

Material

: Soft iron (as per PMS)

(as per PMS)



GUIDELINES FOR FLANGE LEAKAGE CALCULATION 

3.1


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The input in CAESAR shall be as per following steps:

Select Analysis > flanges, to open the “New job name specification” dialog box shown below:

•

File name shall be entered in “Enter the name for the new job file” field. (File name shall be “FlangeN” where N is the flange node no. The flange with maximum load shall be selected).




GUIDELINES FOR FLANGE LEAKAGE CALCULATION •

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In “Enter the data directory” field select the directory from the database dropdown and press “ok”. This will trigger dialogs for flange leakage calculation.

Flange

Refer table as per class from ANSI B16.5, Table 18 to get dimensional data

a. Select flange type

: As per PMS

b. Enter flange class

: As per PMS

c. Flange grade

: Col. 1 of table -1A from B16.5 for the corresponding flange material.

d. Flange outside diameter [A]

: Col.2 (O)

Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server. © L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used, disclosed or reproduced in any format by any non-L&T party without L&T’s prior written permission. All rights reserved. Format EN-FT-4061, Rev 0




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e. Flange inside diameter [B]

: Col.12 (B) i.e. matching ID of pipe welded as per note given in ASME B16.5 table 18.

f. Flange thickness [tf]

: Col.3 (tf).

g. Flange face OD or Lapjt cnt OD

: Refer table – 5 (Don’t use this Value for lap joint)

h. Flange face ID or Lapjt cnt ID

: Col.12 (B).

i.

Small end hub thickness [g0]

: (Col.5 – col.12) /2 = (Ah-B) /2.

j.

Large end hub thickness [g1]

: (Col.4 –col.12) /2 = (X-B) /2.

k. Hub length [h]

: Col.8 (for weld neck) –col.3 =Y- tf.




GUIDELINES FOR FLANGE LEAKAGE CALCULATION 3.3

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Bolts & Gaskets

Refer table as per class from ANSI B16.5, Table 17 for Bolt information. a. Bolt circle diameter

: Col.3. (w)

b.

: Col.5.

No. of bolts

c. Bolt diameter

: Col.6.

d. Bolt initial tightening stress

: Omitted (Default value shall be taken as 45000/d^ ½ Psi), where d = Bolt diameter in inch.





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Refer table 3, ASME B 16.20 / PMS for gasket dimensions. e. Gasket outer dia.

: According to Class/Rating/Ring No.(as per ASME B 16.20, Table 3/4) i.e. (P+A).

f.

: According to Class/Rating/Ring No.(as per ASME B16.20, table 3/4) i.e. (P - A).

Gasket inner dia.

g. Uncompressed gasket thickness

: According to Class/Rating/Ring No.(as per ASME B16.20, table 3/4) i.e. H.

h. Effective gasket modulus

: Elastic Modulus at ambient temperature. (Refer Sec II part D, Table TM-1).

i.

Leak pressure ratio [m]

: Refer table 2-5.1 of mandatory appendix 2 from ASME section –VIII, Division – I.

u.

Gasket seating stress [y]

: Refer table 2-5.1 of mandatory appendix 2 from ASME section –VIII, Division – I.

v

Nubbin width (or ring joint width)

: Width of ring for RTJ gasket.

X

Facing sketch

: Refer table 2-5.1 &2-5.2 of mandatory appendix 2 from ASME Section –VIII, Division I. use Coade equivalent no.

y

Facing column

: Refer table 2-5.1 &2-5.2 of mandatory appendix 2 from ASME Section –VIII, Division I. use Coade equivalent no.





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Material Data:

a) Flange material

: Select from data base dropdown. shall be as per PMS.

b) Bolt material

: Select from database dropdown. shall be as per PMS.

c) Design temperature

: As per line list.

d) Flange allowable @ design temperature

: Considered by CAESAR automatically as per ASME Sec VIII Div 1 .

e) Flange allowable @ ambient temperature

: Considered by CAESAR automatically as per ASME Sec VIII Div 1 .

f)

: Refer table C-6 of B31.3 for flange material and temperature.

Flange modulus of elasticity @ design





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g) Flange modulus of elasticity @ ambient

: Refer table C-6 of B31.3 for flange material and temperature.

h) Bolt allowable @ design temperature

: Considered by CAESAR automatically as per bolt material. (Alternatively refer table A2 of B31.3 for corresponding bolt material and temperature).

i)

Bolt allowable @ ambient temperature

: Considered by CAESAR automatically as per bolt material. (Alternatively refer table A2 of B31.3 for corresponding bolt material and temperature).

j)

Flange allowable stress multiplier

: 1 (Refer para 2-8 of Section VIII Division 1)

k) Bolt allowable stress multiplier ( VIII DIV 2)

3.5

: 2 (Refer article 4-141of Section VIII Division1)

Loads





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a)

Design pressure [P]

: As per line list.

b)

Axial force [optional]

: As per CAESAR output file.

c)

Bending moment [optional]

: As per CAESAR output file.

d)

Disable leakage calculations

: Check to disable the leakage calculation.

e) Disable stress calculations

: Check to disable the stress calculations.

f)

: Check to turn off the report for the ANSI B16.5 equivalent pressure check.

Disable ANSI B16.5 check

3.6 Run the leakage calculation. 3.7 Check the result. 3.8 Necessary changes shall be applied to input file if flange check fails. 3.9 After applying changes repeat above steps.





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Caesar output report:

Pass report sample: FLANGE Flange Flange Flange

LEAKAGE/STRESS CALCULATIONS Inside Diameter [B] (User to verify) ......(mm ) Thickness [t]..............................(mm.) Rating (Optional) ..............................

Bolt Circle Diameter .............................(mm ) Number of Bolts ....................................... Bolt Diameter ....................................(mm ) Bolt Initial Tightening Stress ............(lb./sq.in.)

Uncompressed Gasket Thickness ....................(mm ) Grade of Attached B16_5 ANSI Flange.................... Leak Pressure Ratio [m] ............................... Effective Gasket Modulus ..................(Kg/sq.cm. )

247.630 69.900 900.000 469.900 16.000 34.925

16.000 1.100 5.500 2062620.000

Externally Applied Moment ..... (optional) ....(Kg.m. ) Externally Applied Force ...... (optional) .......(Kg ) Pressure [P]...............................(Kg/sq.cm. )

5000.000 2000.000 22.800

Disable Stress Calculations (Y/N) .....................

N

Flange Type (1-8, see ?-Help or Alt-P to plot) ........

1.000

Flange Outside Diameter [A].......................(mm ) Design Temperature ................................ C

545.000 150.000

Small End Hub Thickness [g0]......................(mm ) Large End Hub Thickness [g1]......................(mm ) Hub Length [h]....................................(mm )

12.700 60.185 114.100

Flange Flange Flange Flange Bolt Bolt Gasket

Allowable @Design Temperature ......(lb./sq.in.) Allowable @Ambient Temperature .....(lb./sq.in.) Modulus of Elasticity @Design ......(Kg/sq.cm. ) Modulus of Elasticity @Ambient .....(Kg/sq.cm. ) Allowable @Design Temperature ......(lb./sq.in.) Allowable @Ambient Temperature .....(lb./sq.in.) Seating Stress [y] .................(lb./sq.in.)

20000.000 20000.000 28288000.000 29500000.000 25000.000 25000.000 18000.000

Flange Allowable Stress Multiplier .................... Bolt Allowable Stress Multiplier (VIII Div 2 4-141) ...

1.500 2.000

Disable Leakage Calculations (Y/N) .................... Disable ANSI B16.5 Checks (Y/N) .......................

N N




GUIDELINES FOR FLANGE LEAKAGE CALCULATION Flange Flange Gasket Gasket Nubbin Facing Facing

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Face OD or Lapjt Cnt OD....................(mm ) Face ID or Lapjt Cnt ID....................(mm ) Outer Diameter ............................(mm ) Inner Diameter ............................(mm ) Width .....................................(mm ) Sketch ......................................... Column .........................................

362.000 248.000 334.980 312.720 11.130 9.000 1.000

Flange Type: (Integral Weld Neck) Effective gasket width parameters: Effective gasket seating width, b......(mm ) Diameter of gasket load reaction, G....(mm )

1.3913 323.8500

SAFETY FACTOR SUMMARY for the different Flange Models analyzed. (SAFETY FACTOR = Allowed/Actual) SAFETY FACTOR Flexibility/Gasket Compression Model (Leakage).. 6.13 ANSI B16.5/Equivalent Pressure (Stress)......... 1.42 ASME Model Operating (Stress)................... 2.00 ASME Model Seating (Stress)..................... 1.21 FLANGE FLEXIBILITY MODEL --------------------------------BOLTED FLANGE CHARACTERISTICS: Initial Tightening Stress in the Bolt (Not the seating stress): 38376 lb./sq.in. Approximate Torque required to induce the above initial stress: 141 Kg.m.

GASKET COMPRESSION: After Initial Boltup (Ci)...........

COMPRESSION (mm ) 0.1128271595

Loss-of Loss-of Loss-of Loss-of

Pressure (Cp)........ Applied Moment (Cm).. Applied Force (Cf)... all loads (CL).......

0.0042581009 0.0133846644 0.0004510691 0.0180938356

Initial minus all Losses (Ci-CL).... For Leak-Proof Joint (Creq)......... Excess available (Ci-Creq) .........

0.0947333276 0.0019454866 0.1108816788

due due due due

to to to to

LEAKAGE SAFETY FACTOR: (If less than one then joint Electronic documents once printed are uncontrolled. Control documents are electronic documents on designated server. © L&T- DEC 2005. Contains confidential and/or proprietary information to L&T and its affiliated companies which shall not be used, disclosed or reproduced in any format by any non-L&T party without L&T’s prior written permission. All rights reserved. Format EN-FT-4061, Rev 0




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leakage is predicted.) (Allowed/Actual) Pressure Only (Ci-Creq)/Cp ............. Force Only (Ci-Creq)/Cf ................ Moment Only (Ci-Creq)/Cm ...............

26.04 245.82 8.28

Pressure+Force+Moment (Ci-Creq)/CL .....

6.13

EQUIVALENT PRESSURE MODEL ---------------------------Equivalent Pressure (Kg/sq.cm. ) ............ ANSI B16.5 Flange Allowable Pressure Rating .

96.88 137.80

STRESS SAFETY FACTOR: (If less than one then joint failure is predicted.) (Allowed/Actual) ANSI B16.5/Equivalent Pressure .................

1.42

ASME SECT VIII DIV 1 STRESS MODEL -----------------------ACCORDING TO A93 APPENDIX S, THE FOLLOWING RIGIDITY FACTORS SHOULD BE LESS THAN 1.0 ASME Rigidity Factor "J", Operating Case ....... ASME Rigidity Factor "J", Seating Case .........

0.0074 0.1012

CALCULATED STRESSES (lb./sq.in.) OPERATING ---------

ALLOW -----

SEATING -------

ALLOW -----

8452 11581 5481 10016 9988

30000 30000 30000 20000 50000

12036 16492 7806 14264 2137

30000 20000 20000 20000 25000

Longitudinal Hub .. Radial Flange ..... Tangential Flange . Maximum Average ... Bolting ...........

"*" Indicates Failure for an item. STRESS SAFETY FACTOR: (If less than one then joint failure is predicted.) (Allowed/Actual)

Longitudinal Hub .... Radial Flange ....... Tangential Flange ... Maximum Average ..... Bolting .............

OPERATING ---------

SEATING -------

3.55 2.59 5.47 2.00 5.01

2.49 1.21 2.56 1.40 11.70





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Failure report sample: FLANGE Flange Flange Flange

LEAKAGE/STRESS CALCULATIONS Inside Diameter [B] (User to verify) ......(mm ) Thickness [t]..............................(mm.) Rating (Optional) ..............................

Bolt Circle Diameter .............................(mm ) Number of Bolts ....................................... Bolt Diameter ....................................(mm ) Bolt Initial Tightening Stress ............(lb./sq.in.)

247.630 69.900 900.000 469.900 16.000 34.925

Uncompressed Gasket Thickness ....................(mm ) Grade of Attached B16_5 ANSI Flange.................... Leak Pressure Ratio [m] ............................... Effective Gasket Modulus ..................(Kg/sq.cm. )

16.000 1.100 5.500 2062620.000

Externally Applied Moment ..... (optional) ....(Kg.m. ) Externally Applied Force ...... (optional) .......(Kg ) Pressure [P]...............................(Kg/sq.cm. )

15000.000 8000.000 22.800

Disable Stress Calculations (Y/N) .....................

N

Flange Type (1-8, see ?-Help or Alt-P to plot) ........

1.000

Flange Outside Diameter [A].......................(mm ) Design Temperature ................................ C

545.000 150.000

Small End Hub Thickness [g0]......................(mm ) Large End Hub Thickness [g1]......................(mm ) Hub Length [h]....................................(mm )

12.700 60.185 114.100

Flange Flange Flange Flange Bolt Bolt Gasket

Allowable @Design Temperature ......(lb./sq.in.) Allowable @Ambient Temperature .....(lb./sq.in.) Modulus of Elasticity @Design ......(Kg/sq.cm. ) Modulus of Elasticity @Ambient .....(Kg/sq.cm. ) Allowable @Design Temperature ......(lb./sq.in.) Allowable @Ambient Temperature .....(lb./sq.in.) Seating Stress [y] .................(lb./sq.in.)

20000.000 20000.000 28288000.000 29500000.000 25000.000 25000.000 18000.000

Flange Allowable Stress Multiplier .................... Bolt Allowable Stress Multiplier (VIII Div 2 4-141) ...

1.500 2.000

Disable Leakage Calculations (Y/N) .................... Disable ANSI B16.5 Checks (Y/N) ....................... Flange Face OD or Lapjt Cnt OD....................(mm ) Flange Face ID or Lapjt Cnt ID....................(mm ) Gasket Outer Diameter ............................(mm )

N N 362.000 248.000 334.980




GUIDELINES FOR FLANGE LEAKAGE CALCULATION Gasket Nubbin Facing Facing

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Inner Diameter ............................(mm ) Width .....................................(mm ) Sketch ......................................... Column .........................................

312.720 11.130 9.000 1.000

Flange Type: (Integral Weld Neck) Effective gasket width parameters: Effective gasket seating width, b......(mm ) Diameter of gasket load reaction, G....(mm )

1.3913 323.8500

SAFETY FACTOR SUMMARY for the different Flange Models analyzed. (SAFETY FACTOR = Allowed/Actual) SAFETY FACTOR Flexibility/Gasket Compression Model (Leakage).. 2.40 ANSI B16.5/Equivalent Pressure (Stress)......... 0.56 ASME Model Operating (Stress)................... 0.79 ASME Model Seating (Stress)..................... 0.85 FLANGE FLEXIBILITY MODEL --------------------------------BOLTED FLANGE CHARACTERISTICS: Initial Tightening Stress in the Bolt (Not the seating stress): 38376 lb./sq.in. Approximate Torque required to induce the above initial stress: 141 Kg.m.

GASKET COMPRESSION: After Initial Boltup (Ci)...........

COMPRESSION (mm ) 0.1128271595

Loss-of Loss-of Loss-of Loss-of

Pressure (Cp)........ Applied Moment (Cm).. Applied Force (Cf)... all loads (CL).......

0.0042581009 0.0401539914 0.0018042764 0.0462163687

Initial minus all Losses (Ci-CL).... For Leak-Proof Joint (Creq)......... Excess available (Ci-Creq) .........

0.0666107908 0.0019454866 0.1108816788

due due due due

to to to to

LEAKAGE SAFETY FACTOR: (If less than one then joint leakage is predicted.) (Allowed/Actual) Pressure Only (Ci-Creq)/Cp .............

26.04




GUIDELINES FOR FLANGE LEAKAGE CALCULATION Force Only (Ci-Creq)/Cf ................ Moment Only (Ci-Creq)/Cm ...............

61.45 2.76

Pressure+Force+Moment (Ci-Creq)/CL .....

2.40

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EQUIVALENT PRESSURE MODEL ---------------------------Equivalent Pressure (Kg/sq.cm. ) ............ ANSI B16.5 Flange Allowable Pressure Rating .

247.47 137.80

STRESS SAFETY FACTOR: (If less than one then joint failure is predicted.) (Allowed/Actual) ANSI B16.5/Equivalent Pressure .................

0.56

ASME SECT VIII DIV 1 STRESS MODEL -----------------------ACCORDING TO A93 APPENDIX S, THE FOLLOWING RIGIDITY FACTORS SHOULD BE LESS THAN 1.0 ASME Rigidity Factor "J", Operating Case ....... ASME Rigidity Factor "J", Seating Case .........

0.0187 0.1442

CALCULATED STRESSES (lb./sq.in.) OPERATING ---------

ALLOW -----

SEATING -------

21345 29248 13844 25297 24850

30000 30000 30000 20000 50000

17149 23498 11122 20324 2137

Longitudinal Hub .. Radial Flange ..... Tangential Flange . Maximum Average ... Bolting ...........

ALLOW ----30000 20000 * 20000 20000 * 25000

"*" Indicates Failure for an item.

STRESS SAFETY FACTOR: (If less than one then joint failure is predicted.) (Allowed/Actual)

Longitudinal Hub .... Radial Flange ....... Tangential Flange ... Maximum Average ..... Bolting .............

OPERATING ---------

SEATING -------

1.41 1.03 2.17 0.79 2.01

1.75 0.85 1.80 0.98 11.70



GUIDELINES FOR FLANGE LEAKAGE CALCULATION 4


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WORK PROCEDURE FOR AUTOPIPE. Flange leakage calculation shall be performed after the piping system is modeled in AutoPIPE. following steps shall be followed: The procedure for calculation shall be explained through a sample calculation. Flange size Flange rating Gasket type Material

: : : :

450 mm 900 # RTJ-octagonal, B16.20 Cl.900 Soft iron (as per PMS)

(as per PMS)

5.1 Select Tools > Flange Analysis from the main menu / Flange analysis icon from toolbar to open flange analysis dialog box.





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5.2 Flange analysis dialog box will appear as shown below.





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5.3 Analysis Analysis tab shall be selected from “Flange Analysis’’ dialog box. Analysis tab can be used to define the general analysis options, e.g. the flange attachment, material library, analysis method etc. Following available fields on the analysis tab shall be defined.

1. Point name

: This field is read-only.

2. No.


3. Flange type


4. Flange rating


5. Nom. pipe size


6. Tag no.


7. Attachment

: Select from drop down list, shall be as per PMS.

8. Analysis method

: Select from drop down list, shall be “ASME Section VIII Div. 1’’.

9. Gasket seating bolt load

: Select from drop down list, shall be “Code required’’.

10. Consider bolt spacing correction : Shall be enabled to consider the bolt spacing correction factor in the analysis. [This option does not apply to the ANSI check analysis method] 11. Analyze

: Shall be enabled to include the flange in the analysis.

12. Max. ratio


13. Notes






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4.4 Load The Load tab shall be used to define the loads applied to each flange, including any external loads (optional). Following available fields on the load tab shall be defined.





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1. Point name


2. No.


3. Flange rating


4. Nom. Pipe size


5. Load combination

: Shall be selected from the drop down list to determine the applied external loads, i.e. axial force & bending moment.

6. Operating case

: Operating case shall be selected from the drop down list to draw the operating pressure and temperature cases.

7. Operating pressure

: Operating press. shall be entered. [ Editable when the “operating case ‘’ field is set to “User’’. Otherwise, this field is read-only’’.

8. Apply B31.3 uninsulated temp.

: Shall be selected to use reduced temp., as defined in section 301.3.2 of B31.3, when determining the allowable stresses.

9. Operating temperature

: Operating temp. shall be entered [ Editable when the “Operating case’’ field is set to “user’’. Otherwise, this field is read-only].

10. Ambient temperature


11. External pressure

: This field is optional. An external pressure is not required to execute the flange analysis.

12. Applied force combination

: Force combination shall be selected from the drop down list to draw the axial force .

13. Axial force

: Axial force shall be entered to calculate moment due to external loads.[ Editable when the “Load combination ‘’ field is set to “user’’. Otherwise, this field is read - only]

14. Applied moment combination

: Applied moment combination Shall be selected from the drop down list to draw the bending moment .

15. Bending moment

: Bending moment shall be entered. [ Editable when the “Load combination” field is set to “user’’. otherwise, this field is read-only]





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4.5 Flange The Flange tab shall be used to define the entire flange dimension, material properties and additional attributes i.e. attachment, reverse, ring type. Following available fields on the flange tab shall be defined.





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1. Point name


2. No.

: This field is read- only.

3. Flange type


4. Flange rating


5. Attachment

: Flange attachment type shall be selected from the drop down list.

6. Joint efficiency factor

: Joint efficiency factor shall be entered only for blind flanges.

7. Lap contact OD

: Outside diameter of the stub flange shall be entered. This field is only available for lap joint flanges.

8. Ring type

: Ring type shall be selected from the drop down list. this option is only available for lap joint and slip-on, with loose attachment, flanges.

9. Reverse

: This field shall be checked to consider the flange as a reversed flange.(not used normally.)

10. Flange material library

: Material library shall be selected from the drop down list.





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11. Flange material

: Select from the drop down list, shall be as per PMS.

12. Select material

: Select the flange material using the ASME material properties dialog, shall be as per PMS.

13. Flange/ Bolt dimensions

: Select the dimension library.

14. Nom. Pipe size


15. Rigidity factor

: Flange rigidity factor shall be entered. This field does not apply to blind flanges. KI = Rigidity factor for integral or optional flange types = 0.3 KL= Rigidity factor for loose type flanges = 0.2

16. Outside diameter [A]

: Considered by AutoPIPE automatically as per selected flange /bolt dimensions library (B16.5/B16.47).

17. Inside diameter [B]

: Considered by AutoPIPE automatically as per selected flange /bolt dimensions library (B16.5/B16.47).

18. Thickness [Tf]

:

Considered by AutoPIPE automatically as per selected flange /bolt dimensions library (B16.5/B16.47).

19. Hub length [Y- Tf]

:

Considered by AutoPIPE automatically as per Selected flange /bolt dimensions library (B16.5/B16.47).

20. Large end hub thickness [g 1]

: Considered by AutoPIPE automatically as per selected flange /bolt dimensions library (B16.5/B16.47). : Considered by Auto PIPE automatically as per Selected flange /bolt dimensions library (B16.5/B16.47).

21. Small end hub thickness [g 0]

22. Allow. Stress at opera. temp. [sf]

: Considered by Auto PIPE automatically as per material selected. (Table A-1 of ASME B31.3).

23. Allow. Stress at Amb. temp. [sf]


24. Density

: Considered by AutoPIPE automatically as per material selected.





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25. Elastic mod. at oper. temp.

: Considered by AutoPIPE automatically as per material selected. (Table C-6 of B31.3).

26. Elastic mod. at Amb. temp.

: Considered by AutoPIPE automatically as per material selected. (Table C-6 of B31.3).

4.6 Pipe The Pipe tab shall be used to define the pipe material and allowable stresses, as well as reference piping dimensions when designing the flange. Following available fields on the pipe tab shall be defined.





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1. Field title

: This field is read only.

2. Point name


3. No.


4. Flange rating


5. Pipe ID


6. Pipe ID material


7. Nom. Pipe size


8. Pipe outside diameter


9. Pipe inside diameter


10. Pipe material library

: Select “Pipe material library” to be used for pipe allowable stresses from the drop down list.





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11. Pipe material

: Pipe material shall be selected from the drop down list. (Note: This drop down list of materials is filtered based on the material library selected on the ‘Analysis’ tab.)

12. Select material

: Pipe material shall be selected using the ASME material properties dialog box.

13. Allow. Stress at oper. temp [Sn]

: Read only, unless “NS’’ is selected as the pipe material.

14. Allow. Stress at Amb. temp [Sn]

: Read only, unless “NS’’ is selected as the pipe material.

4.7 BOLTS The bolts tab can be used to define the bolt material and allowable stresses, as well as the bolt dimensions. Following available fields on the bolts tab shall be defined.

1. Point name


2. No.





GUIDELINES FOR FLANGE LEAKAGE CALCULATION 3. Flange rating

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4. Nom. pipe size


5. Bolt material

: Bolt material shall be selected from the drop down list, shall be as per PMS. [Note: This drop down list of materials is filtered based on the material library selected on the ‘Analysis’ tab.]

6. Select material

: Bolt material shall be selected using the ASME material properties dialog, shall be as per PMS.

7. Thread type

: Bolt thread type shall be selected.

8. Bolt circle diameter [C]

: Considered by AutoPIPE automatically as per B16.5/ B16.47.

9. Number of bolts

: Considered by AutoPIPE automatically as per B16.5/B16.47.

10. Nominal diameter

: Considered by Auto PIPE automatically as per B16.5/ B16.47.

11. Effective diameter


12. Bolt hole diameter


13. Allow. Stress at oper. temp [sb]


14. Allow. Stress at amb. temp [sa]

: Considered by Auto PIPE automatically as per material selected.(Table A-2 of ASME B31.3).





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4.8 GASKET The Gasket tab can be used to define the gasket material and allowable stresses, as well as the gasket dimensions. Following available fields on the gasket tab shall be defined.





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1. Field title


2. Point name


3. No.


4. Flange rating


5. Nom. Pipe size


6. Width [N]

: Considered by Auto PIPE automatically as per B16.20.

7. Inside diameter

: Considered by Auto PIPE automatically as per B16.20.

8. Gasket material

: Gasket material shall be selected from the drop down list, shall be as per PMS.

9. Configuration

: Select the gasket configuration from the drop down list, shall be as per section VIII –Division 1 Appendix 2. Table – 2-5.2.

10. Gasket thickness

: Considered by Auto PIPE automatically as per B16.20. [Note: This field is only editable when the configuration selected requires a gasket thickness to be defined.]

11. Nubbin width

: Considered by Auto PIPE automatically as per B16.20 and Section VIII- Division 1 Appendix 2. [Note: This field is only editable when the configuration requires a nubbin width to be defined.]

12. Strength factor [m]

: Considered by Auto PIPE automatically as per Section VIII –Division 1 Appendix 2, table 2-5.1.

13. Seating stress [y]

: Considered by Auto PIPE automatically as per Section VIII –Division 1 Appendix 2, table 2-5.1.

14. Effective gasket seating width [b]

: Considered by Auto PIPE automatically as per Section VIII- Division 1 Appendix 2 & B16.20. [Note: This field is editable.]

15. Full face gasket

: Shall be selected to consider the gasket “Full Faced’’. [Note: This option is only available for the weld neck flange type.]

16. Load react. Diameter [G]

: Considered by Auto PIPE automatically. [Note: This field is only editable when “user’’ is selected as the gasket material.]





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4.9 ANSI CHECK ANSI Check fields get disabled when “ASME Section VIII Division 1 ‘’ is selected as the flange “Analysis method’’ on the “Analysis” tab.

Notes: 1. ANSI check method shall be performed only when “ANSI Check’’ is selected as the flange analysis method on the Analysis tab. 2. The ANSI flange check can only be executed for flanges set to “NS’’ rating when the “User pressure Temp. Data’’ option is checked, i.e. when user P max data is used in the ANSI Check analysis.





4.10

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“Analyze’’ tab shall be selected for performing flange analysis.

4.11 “Show report’’ tab shall be selected for generating analysis output report.





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Auto PIPE output report: Pass report Sample:

--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:18 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------

* *** ** ** ** ****** ** ** ** ** ** ***** ********* ** ** ** ** ** ** ** ** ** ** ** ** ** ** ***** ** *****

******* ** ** ** ** ******* ** ** **

** ** ** ** ** ** **

******* ** ** ** ** ******* ** ** **

******* ** ** ***** ** ** *******

Pipe Stress Analysis and Design Program Version: 09.05.00.21 Edition: Plus Developed and Maintained by BENTLEY SYSTEMS, INCORPORATED 1600 Riviera Ave., Suite 300 Walnut Creek, CA 94596





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************************************************************ ** ** ** AUTOPIPE FLANGE ANALYSIS ** ** ** ************************************************************

SYSTEM NAME : 01-0010 1

PROJECT ID

: AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ

PREPARED BY

: ______________________________ AP

CHECKED BY

: ______________________________ SK

1ST APPROVER : ______________________________ DKD 2ND APPROVER : ______________________________





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************************************************************ ** ** ** POINT A00 FLANGE # 1 ** ** WELD-NECK ** ** NPS 450.000 mm RATING 900 ** ** ** ************************************************************ VESSEL DESIGN CODE

: ASME Section VIII 2010, Division 1

DIMENSION LIBRARY

: FlangeDimLib.mdb

DIMENSION CODE

: B16-5

MATERIAL LIBRARY

: asme2010.mdb

FLANGE ATTACHMENT

: INTEGRAL

FLANGE CONFIGURATION

: WHOLE

I N P U T S

1.1

FLANGE: -----Material : SA-105 Outside diameter, A : 787.400 Thickness, tf : 101.600 Small End Hub Thk, g0: 12.7000 Hub Length, h : 127.000 Allowable at Oper, Sf: 137.895 Modulus. at Oper, E : 194845.8

1.2

mm mm mm mm MPa MPa

Bore diameter, B : 431.800 Rigidity Factor, K : 0.300 Large End Hub Thk, g1: 66.6750 Bolt Circle Dia., C : 685.800 Allowable at Amb, Sf : 137.895 Modulus. at Amb, E : 199948.8

mm mm mm MPa MPa

PIPE: ---Material : A691-G2.25CR Standard pipe library file : B313-06 Nominal diameter : 450.000 mm Pipe schedule : XS Pipe Inner Diameter : 431.800 mm Allowable at Oper, Sn: 125.898 MPa

Pipe Outer Diameter : Allowable at Amb, Sn :

457.200 mm 137.895 MPa





1.4

1.5

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GASKET: -----Gasket Type : Ring joint iron or soft steel Gasket Config. : Sketch (6) - Column 1 of Table 2-5.2 Inside Diameter : 514.350 mm Seating Width, N : Width of Nubbin, w : 19.050 mm Gasket Thickness : Strength Factor, m : 5.500 Seating Stress, y : Load Reaction Dia., G: 533.400 mm Eff. Press. Width, b:

19.050 0.000 124.106 2.381

BOLTS: ----Material : SA-193-B16-1 No. of Bolts : 20 Bolt Diameter : 47.6250 mm Hub Radial Dist. : 60.3250 mm Bolt Hole Diameter : 50.8000 mm Allowable at Oper, Sb: 137.895 MPa

Allowable at Amb, Sa :

137.895 MPa

At temperature At temperature

120.000 deg C -17.778 deg C

PRESSURE & TEMPERATURE LOADS: ---------------------------Internal pressure : 3.300 N/mm2 External pressure : 0.000 N/mm2 Ambient temp. : 21.100 deg C

Min. Bolt Spacing Eff. Bolt Diameter Outer Edge Dist.

mm mm MPa mm

: 101.6000 mm : 44.1884 mm : 47.6250 mm

: :

D E S I G N

2.0

SUMMARY: ------Design code

: ASME Section VIII Div. I

Flange Thickness

: 101.6000 mm

Flange Volume Flange Diameter Polar Mom Inertia mm4 Bolt Circle Diameter Gasket Strength Factor MPa

: 0.42E+08 mm**3 : 787.400 mm : 0.42E+08 mm4 : :

685.800 mm 5.5000

**Flange Weight Flange Bore Bend Mom Inertia Gasket Load Diameter Gasket Seating Stress

2010

: 191.994 kg : 431.800 mm : 0.35E+08 : :

533.400 mm 124.106

**NOTE: This weight is not used in the static/dynamic analysis. For lap flanges this weight is for the stub flange only. This weight does not include any bolt or nut weight. To set the weight use the Modify > Flange menu option.





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--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:18 AM AutoPIPE Plus 9.5.0.21 -------------------------------------------------------------------------------------R E S U L T S 3.1

ALLOWABLE STRESSES: -----------------1. OPERATING CONDITIONS:

Longitudinal Hub Stress, SH Radial Flange Stress, SR Tangential Flange Stress,ST Average Stress, (SH+SR)/2.0 Average Stress, (SH+ST)/2.0 Bolt Tensile Stress

= = = = = =

INT. PRESS MPa ---------32.090 27.159 22.972 29.624 27.531 28.765

ALLOWABLE MPa --------206.843 137.895 137.895 137.895 137.895 137.895

INT. PRESS RATIO ---------0.155 0.197 0.167 0.215 0.200 0.209

= = = = = =

INT. PRESS MPa ---------67.527 57.151 48.340 62.339 57.934 86.697

ALLOWABLE MPa --------206.843 137.895 137.895 137.895 137.895 137.895

INT. PRESS RATIO ---------0.326 0.414 0.351 0.452 0.420 0.629

**2. GASKET SEATING CONDITIONS:


**NOTE: The gasket seating condition stresses are calculated using the full available bolt load, where Wg = [(Am + Ab)*Sa]/2.

3.2

RIGIDITY CRITERION: -----------------1. OPERATING CONDITIONS:

Rigidity Index,

INT. PRESS

ALLOWABLE

---------0.092

--------1.000

INT. PRESS

ALLOWABLE

---------J = 0.188

--------1.000

J =

INT. PRESS RATIO ---------0.092

2. GASKET SEATING CONDITIONS:

Rigidity Index,






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S T R E S S

4.1

DUE TO FLANGE DIAMETER: ----------------------

K = 1.8235 T = Z = 1.8601 Y = U = 3.7383 e = 0.0071 1/mm d = 2238410. mm**3 ho = 74.0531 mm Lambda = 1.563 4.2

F A C T O R S

1.5749 3.4019

DUE TO FLANGE HUB: -----------------

h/ho G1/G0 F V f

= = = = =

43.5606 5.2500 0.5276 0.0199 1.0000

F O R C E S

&

M O M E N T S

5.1 DUE TO INTERNAL PRESSURE: -----------------------Total hydrostatic end force, H Minimum operating bolt load, Wm1 Min. gasket seating bolt load, Wm2 Design gasket seating bolt load, Wg Ring type moment factor, Fs Bolt spacing correction factor, Bsc

= = = = = =

737411.1 882259.7 495221.2 2659136. 1.0000 1.0000

N N N N





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Mom. Arm x Force = Moment*Bsc*Fs mm N N.m ------------------------------Hydrostatic end force moment,

MD =

hd x Hd 93.662 x 483246.8 = 45262.19

Diff. hydrostatic force moment,

MT =

ht x Ht 101.600 x 254164.4 = 25823.15

Operating gasket load moment,

MG =

hg x Hg 76.200 x 144848.6 = 11037.48

Total gasket seating moment,

Mg =

hg x Wg 76.200 x 2659136. = 202626.6

Ext. Bending & Ax. force moment Moe = 4Me.(xr) + 14167.04 + Where,

Fa.hD = Moment*Fs 0.000 = 14167.04

xr = [I/(0.3846*Ip+I)]*[hD/(C-2*hD)]

Total operating moment, MO=MD+MT+MG+Moe = 96289.86 N.m





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Failure report Sample: --------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:32 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------

* *** ** ** ** ****** ** ** ** ** ** ***** ********* ** ** ** ** ** ** ** ** ** ** ** ** ** ** ***** ** *****

******* ** ** ** ** ******* ** ** **

** ** ** ** ** ** **

******* ** ** ** ** ******* ** ** **

******* ** ** ***** ** ** *******

Pipe Stress Analysis and Design Program Version: 09.05.00.21 Edition: Plus Developed and Maintained by BENTLEY SYSTEMS, INCORPORATED 1600 Riviera Ave., Suite 300 Walnut Creek, CA 94596





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************************************************************ ** ** ** AUTOPIPE FLANGE ANALYSIS ** ** ** ************************************************************

SYSTEM NAME : 01-0010 1

PROJECT ID

: AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ

PREPARED BY

: ______________________________ AP

CHECKED BY

: ______________________________ SK

1ST APPROVER : ______________________________ DKD 2ND APPROVER : ______________________________





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************************************************************ ** ** ** POINT A00 FLANGE # 1 ** ** WELD-NECK ** ** NPS 450.000 mm RATING 900 ** ** ** ************************************************************ VESSEL DESIGN CODE

: ASME Section VIII 2010, Division 1

DIMENSION LIBRARY

: FlangeDimLib.mdb

DIMENSION CODE

: B16-5

MATERIAL LIBRARY

: asme2010.mdb

FLANGE ATTACHMENT

: INTEGRAL

FLANGE CONFIGURATION

: WHOLE

I N P U T S

1.1

FLANGE: -----Material : SA-105 Outside diameter, A : 787.400 Thickness, tf : 101.600 Small End Hub Thk, g0: 12.7000 Hub Length, h : 127.000 Allowable at Oper, Sf: 137.895 Modulus. at Oper, E : 201975.8

1.2

mm mm mm mm MPa MPa

Bore diameter, B : 431.800 Rigidity Factor, K : 0.300 Large End Hub Thk, g1: 66.6750 Bolt Circle Dia., C : 685.800 Allowable at Amb, Sf : 137.895 Modulus. at Amb, E : 199948.8

mm mm mm MPa MPa

PIPE: ---Material : A691-G2.25CR Standard pipe library file : B313-06 Nominal diameter : 450.000 mm Pipe schedule : XS Pipe Inner Diameter : 431.800 mm Allowable at Oper, Sn: 137.895 MPa

Pipe Outer Diameter : Allowable at Amb, Sn :

457.200 mm 137.895 MPa





1.4

1.5

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GASKET: -----Gasket Type : Ring joint iron or soft steel Gasket Config. : Sketch (6) - Column 1 of Table 2-5.2 Inside Diameter : 514.350 mm Seating Width, N : Width of Nubbin, w : 19.050 mm Gasket Thickness : Strength Factor, m : 5.500 Seating Stress, y : Load Reaction Dia., G: 533.400 mm Eff. Press. Width, b:

19.050 0.000 124.106 2.381

BOLTS: ----Material : SA-193-B16-1 No. of Bolts : 20 Bolt Diameter : 47.6250 mm Hub Radial Dist. : 60.3250 mm Bolt Hole Diameter : 50.8000 mm Allowable at Oper, Sb: 137.895 MPa

Allowable at Amb, Sa :

137.895 MPa

At temperature At temperature

-17.778 deg C -17.778 deg C

PRESSURE & TEMPERATURE LOADS: ---------------------------Internal pressure : 20.000 N/mm2 External pressure : 0.000 N/mm2 Ambient temp. : 21.100 deg C

Min. Bolt Spacing Eff. Bolt Diameter Outer Edge Dist.

mm mm MPa mm

: 101.6000 mm : 44.1884 mm : 47.6250 mm

: :

D E S I G N

2.0

SUMMARY: ------Design code

: ASME Section VIII Div. I

Flange Thickness

: 101.6000 mm

Flange Volume kg Flange Diameter mm Polar Mom Inertia mm4 Bolt Circle Diameter mm Gasket Strength Factor MPa

: 0.42E+08 mm**3

2010

**Flange Weight

:

191.994

Flange Bore

:

431.800

: 0.42E+08 mm4

Bend Mom Inertia

: 0.35E+08

:

Gasket Load Diameter

:

533.400

Gasket Seating Stress

:

124.106

:

:

787.400 mm

685.800 mm 5.5000

**NOTE: This weight is not used in the static/dynamic analysis. For lap flanges this weight is for the stub flange only. This weight does not include any bolt or nut weight. To set the weight use the Modify > Flange menu option.





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--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:32 AM AutoPIPE Plus 9.5.0.21 ------------------------------------------------------------------------------------R E S U L T S

3.1

ALLOWABLE STRESSES: -----------------1. OPERATING CONDITIONS:


= = = = = =

INT. PRESS MPa ---------168.658 142.742 120.736 155.700 144.697 174.332

ALLOWABLE MPa --------206.843 137.895 137.895 137.895 137.895 137.895

INT. PRESS RATIO ---------0.815 1.035* 0.876 1.129* 1.049* 1.264*

= = = = = =

INT. PRESS MPa ---------123.112 104.194 88.131 113.653 105.622 158.061

ALLOWABLE MPa --------206.843 137.895 137.895 137.895 137.895 137.895

INT. PRESS RATIO ---------0.595 0.756 0.639 0.824 0.766 1.146*

**2. GASKET SEATING CONDITIONS:


**NOTE: The gasket seating condition stresses are calculated using the full available bolt load, where Wg = [(Am + Ab)*Sa]/2.

3.2

RIGIDITY CRITERION: -----------------1. OPERATING CONDITIONS:

Rigidity Index,

INT. PRESS

ALLOWABLE

---------J = 0.465

--------1.000

INT. PRESS

ALLOWABLE

---------0.343

--------1.000


2. GASKET SEATING CONDITIONS:

Rigidity Index,

J =






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S T R E S S

4.1

DUE TO FLANGE DIAMETER: ----------------------

K = 1.8235 T = Z = 1.8601 Y = U = 3.7383 e = 0.0071 1/mm d = 2238410. mm**3 ho = 74.0531 mm Lambda = 1.563 4.2

F A C T O R S

1.5749 3.4019

DUE TO FLANGE HUB: -----------------

h/ho G1/G0 F V f

= = = = =

43.5606 5.2500 0.5276 0.0199 1.0000

F O R C E S

&

M O M E N T S

5.1 DUE TO INTERNAL PRESSURE: -----------------------Total hydrostatic end force, H Minimum operating bolt load, Wm1 Min. gasket seating bolt load, Wm2 Design gasket seating bolt load, Wg Ring type moment factor, Fs Bolt spacing correction factor, Bsc

= = = = = =

4469158. 5347028. 495221.2 4847986. 1.0000 1.0000

N N N N





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Mom. Arm x Force = Moment*Bsc*Fs mm N N.m ------------------------------Hydrostatic end force moment,

MD =

hd x Hd 93.662 x 2928768. = 274316.3

Diff. hydrostatic force moment,

MT =

ht x Ht 101.600 x 1540390. = 156503.9

Operating gasket load moment,

MG =

hg x Hg 76.200 x 877870.4 = 66893.86

Total gasket seating moment,

Mg =

hg x Wg 76.200 x 4847986. = 369417.3

Ext. Bending & Ax. force moment Moe = 4Me.(xr) + 7715.130 + Where,

Fa.hD = Moment*Fs 655.639 = 8370.770

xr = [I/(0.3846*Ip+I)]*[hD/(C-2*hD)]

Total operating moment, MO=MD+MT+MG+Moe = 506084.8 N.m


235728132-Flange-Leakage.pdf

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