Flange Leakage
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L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page2 of 48
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 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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 1
Rev 0A
Page3 of 48
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, B16.20 Cl.900
Material
: Soft iron (as per PMS)
(as per PMS)
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
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page4 of 48
The input in CAESAR shall be as per following steps: 3.1
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).
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 1
Rev 0A
Page3 of 48
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, B16.20 Cl.900
Material
: Soft iron (as per PMS)
(as per PMS)
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page6 of 48
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.
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 3.3
Rev 0A
Page7 of 48
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.
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION •
3.2
Rev 0A
Page5 of 48
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
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 3.4
Document No PD-DP-0005
Rev 0A
Page9 of 48
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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 3.3
Rev 0A
Page7 of 48
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.
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page8 of 48
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.
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 3.10
Rev 0A
Page12 of 48
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.)
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. )
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
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L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page10 of 48
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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Document No PD-DP-0005
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page14 of 48
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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page15 of 48
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
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
Document No PD-DP-0005
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION Gasket Nubbin Facing Facing
Rev 0A
Page16 of 48
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
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
Document No PD-DP-0005
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION Flange Flange Gasket Gasket Nubbin Facing Facing
Rev 0A
Page13 of 48
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
Document No PD-DP-0005
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page14 of 48
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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page15 of 48
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
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Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page20 of 48
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.
: This field is read-only.
3. Flange type
: This field is read-only.
4. Flange rating
: This field is read-only.
5. Nom. pipe size
: This field is read-only.
6. Tag no.
: This field is read-only.
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
: This field is read-only.
13. Notes
: This field is read-only.
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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
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1. Point name
: This field is read-only.
2. No.
: This field is read-only.
3. Flange rating
: This field is read-only.
4. Nom. Pipe size
: This field is read-only.
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
: This field is read-only.
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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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1. Point name
: This field is read-only.
2. No.
: This field is read- only.
3. Flange type
: This field is read- only.
4. Flange rating
: This field is read- only.
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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
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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
: This field is read-only.
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 [g1]
21. Small end hub thickness [g0]
: 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).
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]
: Considered by Auto PIPE automatically as per material selected. (Table A-1 of ASME B31.3).
24. Density
: Considered by AutoPIPE automatically as per material selected.
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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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1. Field title
: This field is read only.
2. Point name
: This field is read only.
3. No.
: This field is read only.
4. Flange rating
: This field is read only.
5. Pipe ID
: This field is read only.
6. Pipe ID material
: This field is read only.
7. Nom. Pipe size
: This field is read only.
8. Pipe outside diameter
: This field is read only.
9. Pipe inside diameter
: This field is read only.
10. Pipe material library
: Select “Pipe material library” to be used for pipe allowable stresses from the drop down list.
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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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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
: This field is read- only.
2. No.
: This field is read- only.
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L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 3. Flange rating
Rev 0A
Page29 of 48
: This field is read-only.
4. Nom. pipe size
: This field is read-only.
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
: Considered by Auto PIPE automatically as per B16.5/ B16.47.
12. Bolt hole diameter
: Considered by Auto PIPE automatically as per B16.5/ B16.47.
13. Allow. Stress at oper. temp [sb]
: Considered by Auto PIPE automatically as per material selected. (Table A-2 of ASME B31.3).
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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
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1. Field title
: This field is read-only.
2. Point name
: This field is read-only.
3. No.
: This field is read-only.
4. Flange rating
: This field is read-only.
5. Nom. Pipe size
: This field is read-only.
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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GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page32 of 48
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.
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L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
4.10
Rev 0A
Page33 of 48
“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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Document No PD-DP-0005
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GUIDELINES FOR FLANGE LEAKAGE CALCULATION 4.12
Rev 0A
Page34 of 48
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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page35 of 48
--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:18 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------
************************************************************ ** ** ** 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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L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page36 of 48
--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:18 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------
************************************************************ ** ** ** 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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 1.3
1.4
1.5
Rev 0A
Page37 of 48
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.
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
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page38 of 48
--------------------------------------------------------------------------------------------------------------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:
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
**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,
J =
INT. PRESS
ALLOWABLE
---------0.092
--------1.000
INT. PRESS
ALLOWABLE
---------0.188
--------1.000
INT. PRESS RATIO ---------0.092
2. GASKET SEATING CONDITIONS:
Rigidity Index,
J =
INT. PRESS RATIO ---------0.188
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
Document No PD-DP-0005
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 4.12
Rev 0A
Page34 of 48
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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page35 of 48
--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:18 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------
************************************************************ ** ** ** 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 : ______________________________
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page36 of 48
--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:18 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------
************************************************************ ** ** ** 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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION 1.3
1.4
1.5
Rev 0A
Page37 of 48
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.
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
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page38 of 48
--------------------------------------------------------------------------------------------------------------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:
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
**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,
J =
INT. PRESS
ALLOWABLE
---------0.092
--------1.000
INT. PRESS
ALLOWABLE
---------0.188
--------1.000
INT. PRESS RATIO ---------0.092
2. GASKET SEATING CONDITIONS:
Rigidity Index,
J =
INT. PRESS RATIO ---------0.188
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
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page39 of 48
--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:18 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------
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
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
Document No PD-DP-0005
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page40 of 48
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
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
Document No PD-DP-0005
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page41 of 48
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
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
L&T Engineering , Faridabad
Document No PD-DP-0005
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Rev 0A
Page42 of 48
--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:32 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------
************************************************************ ** ** ** 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 : ______________________________
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
L&T Engineering , Faridabad
GUIDELINES FOR FLANGE LEAKAGE CALCULATION
Document No PD-DP-0005
Rev 0A
Page43 of 48
--------------------------------------------------------------------------------------------------------------01-0010 1 05/10/2013 AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ BENTLEY 10:32 AM AutoPIPE Plus 9.5.0.21 ---------------------------------------------------------------------------------------------------------------
************************************************************ ** ** ** 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
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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