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Flange Leakage

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  • L&T Engineering , Faridabad Document No PD-DP-0005 Rev 0A

    GUIDELINES FOR FLANGE LEAKAGE CALCULATION Page2 of 48

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    TABLE OF CONTENTS

    1 SCOPE ........................................................................................................................ 3 2 CODES / STANDARDS............................................................................................... 3 3 WORK PROCEDURE FOR CAESAR ......................................................................... 3 4 WORK PROCEDURE FOR AUTOPIPE. ................................................................... 18 5 REFERENCE DOCUMENTS .................................................................................... 48

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    1 SCOPE This document states the guidelines to perform flange leakage calculation on CAESAR II

    and Auto Pipe V8i.

    2 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.

    3 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 (as per PMS)

    Material : Soft iron (as per PMS)

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    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).

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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.

    3.2 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)

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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 (Dont 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.

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    3.3 Bolts & Gaskets

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

    a. Bolt circle diameter : Col.3. (w)

    b. No. of bolts : Col.5.

    c. Bolt diameter : Col.6.

    d. Bolt initial tightening stress : Omitted (Default value shall be taken as 45000/d^ 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. Gasket inner dia. : According to Class/Rating/Ring No.(as per ASME B16.20, table 3/4) i.e. (P - A).

    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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    3.4 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) Flange modulus of elasticity @ design : Refer table C-6 of B31.3 for flange material and temperature.

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

    3.5 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) Disable ANSI B16.5 check : Check to turn off the report for the ANSI B16.5 equivalent pressure 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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    3.10 Caesar output report:

    Pass report sample:

    FLANGE LEAKAGE/STRESS CALCULATIONS Flange Inside Diameter [B] (User to verify) ......(mm ) 247.630 Flange Thickness [t]..............................(mm.) 69.900 Flange Rating (Optional) .............................. 900.000

    Bolt Circle Diameter .............................(mm ) 469.900 Number of Bolts ....................................... 16.000 Bolt Diameter ....................................(mm ) 34.925 Bolt Initial Tightening Stress ............(lb./sq.in.)

    Uncompressed Gasket Thickness ....................(mm ) 16.000 Grade of Attached B16_5 ANSI Flange.................... 1.100 Leak Pressure Ratio [m] ............................... 5.500 Effective Gasket Modulus ..................(Kg/sq.cm. ) 2062620.000

    Externally Applied Moment ..... (optional) ....(Kg.m. ) 5000.000 Externally Applied Force ...... (optional) .......(Kg ) 2000.000 Pressure [P]...............................(Kg/sq.cm. ) 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 ) 545.000 Design Temperature ................................ C 150.000

    Small End Hub Thickness [g0]......................(mm ) 12.700 Large End Hub Thickness [g1]......................(mm ) 60.185 Hub Length [h]....................................(mm ) 114.100

    Flange Allowable @Design Temperature ......(lb./sq.in.) 20000.000 Flange Allowable @Ambient Temperature .....(lb./sq.in.) 20000.000 Flange Modulus of Elasticity @Design ......(Kg/sq.cm. ) 28288000.000 Flange Modulus of Elasticity @Ambient .....(Kg/sq.cm. ) 29500000.000 Bolt Allowable @Design Temperature ......(lb./sq.in.) 25000.000 Bolt Allowable @Ambient Temperature .....(lb./sq.in.) 25000.000 Gasket Seating Stress [y] .................(lb./sq.in.) 18000.000

    Flange Allowable Stress Multiplier .................... 1.500 Bolt Allowable Stress Multiplier (VIII Div 2 4-141) ... 2.000

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

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    Flange Face OD or Lapjt Cnt OD....................(mm ) 362.000 Flange Face ID or Lapjt Cnt ID....................(mm ) 248.000 Gasket Outer Diameter ............................(mm ) 334.980 Gasket Inner Diameter ............................(mm ) 312.720 Nubbin Width .....................................(mm ) 11.130 Facing Sketch ......................................... 9.000 Facing Column ......................................... 1.000

    Flange Type: (Integral Weld Neck)

    Effective gasket width parameters: Effective gasket seating width, b......(mm ) 1.3913 Diameter of gasket load reaction, G....(mm ) 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: COMPRESSION (mm ) After Initial Boltup (Ci)........... 0.1128271595

    Loss-of due to Pressure (Cp)........ 0.0042581009 Loss-of due to Applied Moment (Cm).. 0.0133846644 Loss-of due to Applied Force (Cf)... 0.0004510691 Loss-of due to all loads (CL)....... 0.0180938356

    Initial minus all Losses (Ci-CL).... 0.0947333276 For Leak-Proof Joint (Creq)......... 0.0019454866 Excess available (Ci-Creq) ......... 0.1108816788

    LEAKAGE SAFETY FACTOR: (If less than one then joint

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    leakage is predicted.) (Allowed/Actual)

    Pressure Only (Ci-Creq)/Cp ............. 26.04 Force Only (Ci-Creq)/Cf ................ 245.82 Moment Only (Ci-Creq)/Cm ............... 8.28

    Pressure+Force+Moment (Ci-Creq)/CL ..... 6.13

    EQUIVALENT PRESSURE MODEL ----------------------------

    Equivalent Pressure (Kg/sq.cm. ) ............ 96.88 ANSI B16.5 Flange Allowable Pressure Rating . 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 ....... 0.0074 ASME Rigidity Factor "J", Seating Case ......... 0.1012

    CALCULATED STRESSES (lb./sq.in.)

    OPERATING ALLOW SEATING ALLOW --------- ----- ------- -----

    Longitudinal Hub .. 8452 30000 12036 30000 Radial Flange ..... 11581 30000 16492 20000 Tangential Flange . 5481 30000 7806 20000 Maximum Average ... 10016 20000 14264 20000 Bolting ........... 9988 50000 2137 25000

    "*" Indicates Failure for an item.

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

    OPERATING SEATING --------- -------

    Longitudinal Hub .... 3.55 2.49 Radial Flange ....... 2.59 1.21 Tangential Flange ... 5.47 2.56 Maximum Average ..... 2.00 1.40 Bolting ............. 5.01 11.70

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    Failure report sample:

    FLANGE LEAKAGE/STRESS CALCULATIONS Flange Inside Diameter [B] (User to verify) ......(mm ) 247.630 Flange Thickness [t]..............................(mm.) 69.900 Flange Rating (Optional) .............................. 900.000

    Bolt Circle Diameter .............................(mm ) 469.900 Number of Bolts ....................................... 16.000 Bolt Diameter ....................................(mm ) 34.925 Bolt Initial Tightening Stress ............(lb./sq.in.)

    Uncompressed Gasket Thickness ....................(mm ) 16.000 Grade of Attached B16_5 ANSI Flange.................... 1.100 Leak Pressure Ratio [m] ............................... 5.500 Effective Gasket Modulus ..................(Kg/sq.cm. ) 2062620.000

    Externally Applied Moment ..... (optional) ....(Kg.m. ) 15000.000 Externally Applied Force ...... (optional) .......(Kg ) 8000.000 Pressure [P]...............................(Kg/sq.cm. ) 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 ) 545.000 Design Temperature ................................ C 150.000

    Small End Hub Thickness [g0]......................(mm ) 12.700 Large End Hub Thickness [g1]......................(mm ) 60.185 Hub Length [h]....................................(mm ) 114.100

    Flange Allowable @Design Temperature ......(lb./sq.in.) 20000.000 Flange Allowable @Ambient Temperature .....(lb./sq.in.) 20000.000 Flange Modulus of Elasticity @Design ......(Kg/sq.cm. ) 28288000.000 Flange Modulus of Elasticity @Ambient .....(Kg/sq.cm. ) 29500000.000 Bolt Allowable @Design Temperature ......(lb./sq.in.) 25000.000 Bolt Allowable @Ambient Temperature .....(lb./sq.in.) 25000.000 Gasket Seating Stress [y] .................(lb./sq.in.) 18000.000

    Flange Allowable Stress Multiplier .................... 1.500 Bolt Allowable Stress Multiplier (VIII Div 2 4-141) ... 2.000

    Disable Leakage Calculations (Y/N) .................... N Disable ANSI B16.5 Checks (Y/N) ....................... N Flange Face OD or Lapjt Cnt OD....................(mm ) 362.000 Flange Face ID or Lapjt Cnt ID....................(mm ) 248.000 Gasket Outer Diameter ............................(mm ) 334.980

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    Gasket Inner Diameter ............................(mm ) 312.720 Nubbin Width .....................................(mm ) 11.130 Facing Sketch ......................................... 9.000 Facing Column ......................................... 1.000

    Flange Type: (Integral Weld Neck)

    Effective gasket width parameters: Effective gasket seating width, b......(mm ) 1.3913 Diameter of gasket load reaction, G....(mm ) 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: COMPRESSION (mm ) After Initial Boltup (Ci)........... 0.1128271595

    Loss-of due to Pressure (Cp)........ 0.0042581009 Loss-of due to Applied Moment (Cm).. 0.0401539914 Loss-of due to Applied Force (Cf)... 0.0018042764 Loss-of due to all loads (CL)....... 0.0462163687

    Initial minus all Losses (Ci-CL).... 0.0666107908 For Leak-Proof Joint (Creq)......... 0.0019454866 Excess available (Ci-Creq) ......... 0.1108816788

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

    Pressure Only (Ci-Creq)/Cp ............. 26.04

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    Force Only (Ci-Creq)/Cf ................ 61.45 Moment Only (Ci-Creq)/Cm ............... 2.76

    Pressure+Force+Moment (Ci-Creq)/CL ..... 2.40

    EQUIVALENT PRESSURE MODEL ----------------------------

    Equivalent Pressure (Kg/sq.cm. ) ............ 247.47 ANSI B16.5 Flange Allowable Pressure Rating . 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 ....... 0.0187 ASME Rigidity Factor "J", Seating Case ......... 0.1442

    CALCULATED STRESSES (lb./sq.in.)

    OPERATING ALLOW SEATING ALLOW --------- ----- ------- -----

    Longitudinal Hub .. 21345 30000 17149 30000 Radial Flange ..... 29248 30000 23498 20000 * Tangential Flange . 13844 30000 11122 20000 Maximum Average ... 25297 20000 20324 20000 * Bolting ........... 24850 50000 2137 25000

    "*" Indicates Failure for an item.

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

    OPERATING SEATING --------- -------

    Longitudinal Hub .... 1.41 1.75 Radial Flange ....... 1.03 0.85 Tangential Flange ... 2.17 1.80 Maximum Average ..... 0.79 0.98 Bolting ............. 2.01 11.70

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    4 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 : 450 mm Flange rating : 900 # Gasket type : RTJ-octagonal, B16.20 Cl.900 (as per PMS) Material : Soft iron (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. : 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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    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 : 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 Page23 of 48

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

    21. Small end hub thickness [g0] : 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 Page26 of 48

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    disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    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 : 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 Page28 of 48

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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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    GUIDELINES FOR FLANGE LEAKAGE CALCULATION Page29 of 48

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    disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    3. Flange rating : 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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    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 : 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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    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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    disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    4.10 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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    disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    4.12 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

  • L&T Engineering , Faridabad Document No PD-DP-0005 Rev 0A

    GUIDELINES FOR FLANGE LEAKAGE CALCULATION Page35 of 48

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    disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    -------------------------------------------------------------------------------------

    ---------------------------

    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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    GUIDELINES FOR FLANGE LEAKAGE CALCULATION Page36 of 48

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    disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    --------------------------------------------------------------------------------------

    --------------------------

    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 mm Bore diameter, B : 431.800 mm Thickness, tf : 101.600 mm Rigidity Factor, K : 0.300 Small End Hub Thk, g0: 12.7000 mm Large End Hub Thk, g1: 66.6750 mm Hub Length, h : 127.000 mm Bolt Circle Dia., C : 685.800 mm Allowable at Oper, Sf: 137.895 MPa Allowable at Amb, Sf : 137.895 MPa Modulus. at Oper, E : 194845.8 MPa Modulus. at Amb, E : 199948.8 MPa

    1.2 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 Pipe Outer Diameter : 457.200 mm Allowable at Oper, Sn: 125.898 MPa Allowable at Amb, Sn : 137.895 MPa

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    1.3 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 : 19.050 mm Width of Nubbin, w : 19.050 mm Gasket Thickness : 0.000 mm Strength Factor, m : 5.500 Seating Stress, y : 124.106 MPa Load Reaction Dia., G: 533.400 mm Eff. Press. Width, b: 2.381 mm

    1.4 BOLTS: -----

    Material : SA-193-B16-1 No. of Bolts : 20 Min. Bolt Spacing : 101.6000 mm Bolt Diameter : 47.6250 mm Eff. Bolt Diameter : 44.1884 mm Hub Radial Dist. : 60.3250 mm Outer Edge Dist. : 47.6250 mm Bolt Hole Diameter : 50.8000 mm Allowable at Oper, Sb: 137.895 MPa Allowable at Amb, Sa : 137.895 MPa

    1.5 PRESSURE & TEMPERATURE LOADS: ----------------------------

    Internal pressure : 3.300 N/mm2 At temperature : 120.000 deg C External pressure : 0.000 N/mm2 At temperature : -17.778 deg C Ambient temp. : 21.100 deg C

    D E S I G N

    2.0 SUMMARY: -------

    Design code : ASME Section VIII Div. I 2010

    Flange Thickness : 101.6000 mm

    Flange Volume : 0.42E+08 mm**3 **Flange Weight : 191.994 kg Flange Diameter : 787.400 mm Flange Bore : 431.800 mm Polar Mom Inertia : 0.42E+08 mm4 Bend Mom Inertia : 0.35E+08

    mm4 Bolt Circle Diameter : 685.800 mm Gasket Load Diameter : 533.400 mm Gasket Strength Factor : 5.5000 Gasket Seating Stress : 124.106

    MPa

    **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: INT. PRESS ALLOWABLE INT. PRESS MPa MPa RATIO ---------- --------- ----------

    Longitudinal Hub Stress, SH = 32.090 206.843 0.155 Radial Flange Stress, SR = 27.159 137.895 0.197 Tangential Flange Stress,ST = 22.972 137.895 0.167 Average Stress, (SH+SR)/2.0 = 29.624 137.895 0.215 Average Stress, (SH+ST)/2.0 = 27.531 137.895 0.200 Bolt Tensile Stress = 28.765 137.895 0.209

    **2. GASKET SEATING CONDITIONS: INT. PRESS ALLOWABLE INT. PRESS MPa MPa RATIO ---------- --------- ----------

    Longitudinal Hub Stress, SH = 67.527 206.843 0.326 Radial Flange Stress, SR = 57.151 137.895 0.414 Tangential Flange Stress,ST = 48.340 137.895 0.351 Average Stress, (SH+SR)/2.0 = 62.339 137.895 0.452 Average Stress, (SH+ST)/2.0 = 57.934 137.895 0.420 Bolt Tensile Stress = 86.697 137.895 0.629

    **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: INT. PRESS ALLOWABLE INT. PRESS RATIO ---------- --------- ----------

    Rigidity Index, J = 0.092 1.000 0.092

    2. GASKET SEATING CONDITIONS: INT. PRESS ALLOWABLE INT. PRESS RATIO ---------- --------- ----------

    Rigidity Index, J = 0.188 1.000 0.188

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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 --------------------------------------------------------------------------------------

    --------------------------

    S T R E S S F A C T O R S

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

    K = 1.8235 T = 1.5749 Z = 1.8601 Y = 3.4019 U = 3.7383 e = 0.0071 1/mm d = 2238410. mm**3 ho = 74.0531 mm Lambda = 1.563

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

    h/ho = 43.5606 G1/G0 = 5.2500 F = 0.5276 V = 0.0199 f = 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 = 737411.1 N Minimum operating bolt load, Wm1 = 882259.7 N Min. gasket seating bolt load, Wm2 = 495221.2 N Design gasket seating bolt load, Wg = 2659136. N Ring type moment factor, Fs = 1.0000 Bolt spacing correction factor, Bsc = 1.0000

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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) + Fa.hD = Moment*Fs 14167.04 + 0.000 = 14167.04

    Where, 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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    GUIDELINES FOR FLANGE LEAKAGE CALCULATION Page42 of 48

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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 -------------------------------------------------------------------------------------

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    ** **

    ** AUTOPIPE FLANGE ANALYSIS ** ** **

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    SYSTEM NAME : 01-0010 1

    PROJECT ID : AMMONIA PLANT FEEDSTOCK CHANGEOVER PROJ

    PREPARED BY : ______________________________ AP

    CHECKED BY : ______________________________ SK

    1ST APPROVER : ______________________________ DKD

    2ND APPROVER : ______________________________

  • L&T Engineering , Faridabad Document No PD-DP-0005 Rev 0A

    GUIDELINES FOR FLANGE LEAKAGE CALCULATION Page43 of 48

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    disclosed or reproduced in any format by any non-L&T party without L&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    -------------------------------------------------------------------------------------

    ---------------------------

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

    9.5.0.21 -------------------------------------------------------------------------------------

    ---------------------------

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    ** **

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

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    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 mm Bore diameter, B : 431.800 mm Thickness, tf : 101.600 mm Rigidity Factor, K : 0.300 Small End Hub Thk, g0: 12.7000 mm Large End Hub Thk, g1: 66.6750 mm Hub Length, h : 127.000 mm Bolt Circle Dia., C : 685.800 mm Allowable at Oper, Sf: 137.895 MPa Allowable at Amb, Sf : 137.895 MPa Modulus. at Oper, E : 201975.8 MPa Modulus. at Amb, E : 199948.8 MPa

    1.2 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 Pipe Outer Diameter : 457.200 mm Allowable at Oper, Sn: 137.895 MPa Allowable at Amb, Sn : 137.895 MPa

  • L&T Engineering , Faridabad Document No PD-DP-0005 Rev 0A

    GUIDELINES FOR FLANGE LEAKAGE CALCULATION Page44 of 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&Ts prior written permission. All rights reserved. Format EN-FT-4061, Rev 0

    1.3 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 : 19.050 mm Width of Nubbin, w : 19.050 mm Gasket Thickness : 0.000 mm Strength Factor, m : 5.500 Seating Stress, y : 124.106 MPa Load Reaction Dia., G: 533.400 mm Eff. Press. Width, b: 2.381 mm

    1.4 BOLTS: -----

    Material : SA-193-B16-1 No. of Bolts : 20 Min. Bolt Spacing : 101.6000 mm Bolt Diameter : 47.6250 mm Eff. Bolt Diameter : 44.1884 mm Hub Radial Dist. : 60.3250 mm Outer Edge Dist. : 47.6250 mm Bolt Hole Diameter : 50.8000 mm Allowable at Oper, Sb: 137.895 MPa Allowable at Amb, Sa : 137.895 MPa

    1.5 PRESSURE & TEMPERATURE LOADS: ----------------------------

    Internal pressure : 20.000 N/mm2 At temperature : -17.778 deg C External pressure : 0.000 N/mm2 At temperature : -17.778 deg C Ambient temp. : 21.100 deg C

    D E S I G N

    2.0 SUMMARY: -------

    Design code : ASME Section VIII Div. I 2010

    Flange Thickness : 101.6000 mm

    Flange Volume : 0.42E+08 mm**3 **Flange Weight : 191.994 kg

    Flange Diameter : 787.400 mm Flange Bore : 431.800 mm

    Polar Mom Inertia : 0.42E+08 mm4 Bend Mom Inertia : 0.35E+08 mm4

    Bolt Circle Diameter : 685.800 mm Gas