Girth Flange load Calculation using by FEA Techniques.

Kingston Rivington
ASME Authorized Inspector (A, AR)
ASNT Level 3 RT, PT, MT, UT, VT, ET, LT
ISO 9712 Level 3 PAUT/TOFD, API 510,570,653
[email protected] Ref: Vol-8-1-2020

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1. INTRODUCTION:

The Bolted flange connections are used on pressure vessels since they permit easy disassembly of
components (such as heat exchanger channel head) for maintenance purpose. The bolted flange may in
the form of Slip-on flange, Socket weld type, blind flange, a loose-type flange, or an integral-type flange.
An early method to the load & stress analyse of bolted flange connections with gaskets that was
developed by Taylor Forge. It is believed that this method was further developed by the ASME Code
Committee for use in various sections of the ASME Code. The flange design rules are available in ASME
Div.VIII-1 Appendix 2 and Section 4.16 of VIII-2. This paper presents the design analysis of integral bolted
flange for Heat exchanger channel body flange. Since Bolted flange connection have the vital role to hold
the internal pressure and as well various stresses that imposed on the heat exchangers., it should be
designed in such a way that it can with stand the indented purpose during it’s service span. A model of
integral type girth or body flange created in ANSYS workbench & stresses are calculated using by ANSYS
workbench software. The mathematical calculation is also made by set of design rules as per ASME Div 1
Appendix 2. The results obtained by both the methods are compared with allowable stress value for safe
designing. Generally, all load and stress calculations are made for Flange operating condition and gasket
seating condition. Here flange operating condition approach has been chosen for comparison study..

2. GIRTH FLANGE DATA.

DESIGN DATA
INTEGRAL
Flange Type TYPE WITH
HUB
Flange Design Pressure (INTERNAL) Pi 1.00 MPa
o
Design Temperature of Flange TD 100 C
Corrosion Allowance of Flange c 0 mm
SA-350M Gr.
Flange MOC
LF2 Cl.1
SA-320M Gr.
Bolting MOC
L7
Spiral wound+
Gasket / O Ring
carbon filling
Allowable Stress for Shell at Design Temp. (i.e. at 100 oC) SnO 118 MPa
Allowable Stress for Shell at Atmospheric Temp. (i.e. at 30 oC) SnA 118 MPa
Allowable Stress for Flange Material at Design Temp. (i.e. at 100 oC) SfO 138 MPa
o
Allowable Stress for Flange Material at Atmospheric Temp. (i.e. at 30 C) SfA 138 MPa
Allowable Stress for Bolting Material at Design Temp. (i.e. at 100 oC) Sb 138 MPa
Allowable Stress for Bolting Material at Atmosheric Temp. (i.e. at 30 oC) Sa 138 MPa

Gasket / O Ring Seating Width N 32 mm

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Basic Gasket Seating Width b0 =N/2
16 mm
Effective Gasket Seating Width (b=b0 for b0< 6mm b1 10.00 mm
b = 2.5 Sqrt(b0) for b0>6mm) b 10.00
Gasket Factor m 2.50
Gasket / O Ring Design Seating Stress y 69 MPa
Outside Diameter of Gasket Contact Face Go 988.1 mm
Gasket Load Reaction Diameter G 963 mm
Outside Diameter of Flange A 1180 mm
Inside Diameter of Flange B 889.0 mm
Provided Thickness of Flange with Hub tf 142 mm
Required Thickness of Flange t 82 mm
Thickness of Hub at small End g0 17 mm
Thickness Hub at back of Flange g1 26 mm
Hub Length h 60 mm
Hub Factor h0 = Sqrt (Bg0) = SQRT (646 x 7) h0 122.93 mm
Bolt circle diameter C 1098 mm
Radial Distance from bolt circle to point R = 0.5(C - B) - g1
R = 0.5 x (806.4 -
of intersection of hub and back of flange R 78.5 mm
646) - 19
Modulus of Elasticity for the Flange at Design Temp. (i.e. at 100 oC) EfO 200000 MPa
Modulus of Elasticity for the Flange at Atmospheric Temp. (i.e. at 30 oC) EfA 201733 MPa
0.3
Rigidity Factor for Integral Type Flanges KI

Fig 1 - Dimension of Girth flange Fig 2 -3D Geometry

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3.MATHEMATICAL APPROACH :(As per ASME SECTION VIII Division 1 Appendix -2)

3.1. Bolt Load Required Under Internal Pressure

Required Bolt Load Under Operating Condition Wm1 = H + HP

Total Hydrostatic End Force H = 0.785 x G2 x Pi
H 727984.67 N
Total Joint Contact Surface Compression Load HP = 2b x (3.14GmPi)
HP 151191.00 N
Hence Wm1 = H+HP Wm1 879175.67 N
Void Wm2 = 3.14 b G y
Wm2 2086435.8 N
Total Cross-Sectional Area Am is Maximum of (Am1 and Am2)

Area Am1 = Wm1 / Sb Am1 6370.84 mm2

Area Am2 = Wm2 / Sa Am2 15119.10 mm2

So Total Cross Sectional Area MAX (Am1, Am2)

Am 15119.10 mm2
Selected Stud Bolt Size M 32 mm
Root Area of Bolt AR 698.75 mm2
Minimum Number of Bolts Required NM = Total C/s Area / Root Area of Bolts

NM 24.00 Nos
Actual Number of Bolts Provided
Total Bolt area Ab = AR x N Ab 16770.00 mm2
Since Total Bolt Area (Ab) > Total C/s Area(Am) Selected Bolt Size is OK
Flange Design Bolt Load ( W )
Bolt Load at Operating Condition WO = Wm1
WO 879175.67 N

3.2 Flange Hydrostat condition

Total Hydrostatic End Force H H 727984.67 N

Total Hydrostatic End Force on area inside of flange HD = 0.785 x B2 x Pi
HD 620401.99 N
Gasket Load HG = WO - H HG 151191.00 N
Total Joint Contact Surface Compression Load HP 151191.00 N
But HT = Difference Between H and H D HT = H - HD
HT 107582.68 N

3.3 Flange Moment Calculations

Total Flange Moment at Operating Condition M0 M0 = MT + MG + MD

= HT hT + HG hG+ HD hD
Radial distance from the bolt circle to the circle on which hD = R + 0.5g1
HD acts ( As Per Table 2-6 ) 91.50 mm
Radial distance from gasket load reaction to BCD hG =C-G/2
( As Per Table 2-6 ) 67.50 mm
Radial distance from BCD to circle on HT acts hT = R + g1 + hG / 2
( As Per Table 2-6 ) 86.00 mm
Hence M0 at Operating Condittion M0 = HT hT + HG hG+ HD hD
M0 76224284.61 Nmm

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3.4 Flange Factors in Formula Form

Value, g1/g0 = 30.13 / 9.53 g1/g0 1.529

Value, h/ho = 81.2 / 53.89 h/ho 0.488
Factor A = (g1/go) - 1 A 0.529
Factor C = 43.68 (h/ho)4 C 2.478
Factor C1 = 1/3 + A/12 C1 0.377
Factor C2 = 5/42 + 17A/336 C2 0.146
Factor C3 = 1/210 + A/360 C3 0.006
Factor C4 = 11/360 + 59A/5040 + (1+3A)/C C4 1.081
Factor C5 = 1/90 + 5A/1008 - (1+A)3/C C5 -1.430
Factor C6 = 1/120 + 17A/5040 + 1/C C6 0.414
Factor C7 = 215/2772 +51A/1232 + (60/7 + 225A/14 + 75A2/7 + 5A3/2)/C C7 8.352
Factor C8 = 31/6930 + 128A/45,045 + (6/7 + 15A/7 + 12A2/7 + 5A3/11)/C C8 1.031
2 3
Factor C9 = 533/30,240 + 653A/73,920 + (1/2 + 33A/14 + 39A /28 + 25A /84)/C C9 0.903
Factor C10 = 29/3780 + 3A/704 - (1/2 + 33A/14 + 81A2/28 + 13A3/12)/C C10 -1.087
Factor C11 = 31/6048 + 1763A/665,280 + (1/2 + 6A/7 + 15A2/28 + 5A3/42)/C C11 0.459
Factor C12 = 1/2925 + 71A/300,300 + (8/35 + 18A/35 + 156A2/385 + 6A3/55)/C C12 0.255
2 3
Factor C13 = 761/831,600 + 937A/1,663,200 + (1/35 + 6A/35 + 11A /70 + 3A /70)/C C13 0.070
Factor C14 = 197/415,800 + 103A/332,640 - (1/35 + 6A/35 + 17A2/70 + A3/10)/C C14 -0.081
Factor C15 = 233/831,600 + 97A/554,400 + (1/35 + 3A/35 + A2/14 + 2A3/105)/C C15 0.039
Factor C16 = C1C7C12 + C2C8C3 + C3C8C2 - (C32C7 + C82C1 + C22C12) C16 0.398
Factor C17 = [C4C7C12 + C2C8C13 + C3C8C9 - (C13C7C3 + C82C4 + C12C2C9)]/C16 C17 2.846
Factor C18 = [C5C7C12 + C2C8C14 + C3C8C10 - (C14C7C3 + C82C5 + C12C2C10)]/C16 C18 -3.769
Factor C19 = [C6C7C12 + C2C8C15 + C3C8C11 - (C15C7C3 + C82C6 + C12C2C11)]/C16 C19 1.083
Factor C20 = [C1C9C12 + C4C8C3 + C3C13C2 - (C32C9 + C13C8C1 + C12C4C2)]/C16 C20 0.067
Factor C21 = [C1C10C12 + C5C8C3 + C3C14C2 - (C32C10 + C14C8C1 + C12C5C2)]/C16 C21 -0.073
Factor C22 = [C1C11C12 + C6C8C3 + C3C15C2 - (C32C11 + C15C8C1 + C12 C6C2)]/C16 C22 0.041
Factor C23 = [C1C7C13 + C2C9C3 + C4C8C2 - (C3C7C4 + C8C9C1 + C22C13)]/C16 C23 -0.065
Factor C24 = [C1C7C14 + C2C10C3 + C5C8C2 - (C3C7C5 + C8C10C1 + C22C14)]/C16 C24 0.070
Factor C25 = [C1C7C15 + C2C11C3 + C6C8C2 - (C3C7C6 + C8C11C1 + C22C15)]/C16 C25 -0.035
Factor C26 = - (C/4)1/4 C26 -0.887
Factor C27 = C20 - C17 - 5/12 + C17C26 C27 -5.721
Factor C28 = C22 - C19 - 1/12 + C19C26 C28 -2.087
Factor C29 = - (C/4)1/2 C29 -0.787

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Factor C30 = - (C/4)3/4 C30 -0.698
Factor C31 = 3A/2 - C17C30 C31 2.782
Factor C32
C32 1.257
= 1/2 - C19C30
Factor C33 = 0.5C26C32 + C28C31C29 - (0.5C30C28 + C32C27C29) C33 -2.375
Factor C34 = 1/12 + C18 - C21 - C18C26 C34 -6.957
Factor C35 = - C18(C/4)3/4 C35 2.633
Factor C36 = (C28C35C29 - C32C34C29)/C33 C36 1.076
Factor C37 = [0.5C26C35 + C34C31C29 - (0.5C30C34 + C35C27C29)]/C33 C37 0.092
Factor E1 = C17C36 + C18 + C19C37 E1 -0.606
Factor E2 = C20C36 + C21 + C22C37 E2 0.002
Factor E3 = C23C36 + C24 + C25C37 E3 -0.003
Factor E4 = 1/4 + C37/12 + C36/4 - E3/5 - 3E2/2 - E1 E4 1.130
-0.356
Factor E5 = E1(1/2 + A/6) + E2(1/4 + 11A/84) + E3(1/70 + A/105) E5

Factor E6
= E5 - C36(7/120 + A/36 + 3A/C) - 1/40 - A/72 - C37(1/60 + A/120 + 1/C) E6 -1.188

Factor K =A/B = 485 / 304.74

K 1.329
2 2
Factor T = [ K (1 + 8.55246 log10K) - 1 ] / [ (1.04720 + 1.9448K ) (K-1) ]
T 1.785
Factor Z = (K2 + 1) / (K2 - 1)
Z 3.612
Factor Y = ( 1 / K-1 ) x { 0.66845 + 5.71690 x [ (K2log10K) / K2 -1 ] }
Y 6.983
Factor U = [ K2 (1 + 8.55246 log10K) - 1 ] / [ 1.36136 (K2 - 1) (K - 1) ]
U 7.673
Factor F = - E6 / (C/2.73)1/4 x [ (1+A)3 / C ]
F 0.843
Factor V = E4 / (2.73/C)1/4 x (1+A)3
V 0.308
Factor f = C36 / (1+A) ( Hub Stress Correction Factor)
f 0.704
Factor e = F / h0
e 0.007

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 Factor d = U/V h0 g02 d 883993.762

Factor L = ( te + 1/T ) + ( t3/d ) L 1.499

3.5 CALCULATION OF STRESS AT OPERATING CONDITION (APPENDIX 2 SECTION 2-7)

Fig 3 – Stress orientation

Longitudinal Hub Stress SH = f M0 / L g12 B

SH 59.5 MPa

= (1.33 te + 1) M0 / L t2
Radial Flange Stress SR
B
SR 14.9 MPa

Tangential Flange Stress ST = (Y M0 / t2 B) - Z SR

ST 35.3 MPa

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3. FINITE ELEMENT ANALYSIS (Ansys workbench 19.2)
The finite element details are given below table 1& 2

Fig 4 – 3D Modeler

TABLE 1
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Use Geometry
Display Style
Setting
Defaults
Physics Preference Mechanical
Element Order Program Controlled
Element Size Default
Sizing
Use Adaptive Sizing Yes
Resolution Default (2)
Mesh Defeaturing Yes
Defeature Size Default
Transition Fast
Span Angle Centre Coarse
Initial Size Seed Assembly

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 Bounding Box Diagonal 1237.6 mm
Average Surface Area 21002 mm²
Minimum Edge Length 13.0 mm
Quality
Check Mesh Quality yes
Standard
Error Limits
Mechanical
Target Quality Default (0.050000)
Smoothing Medium
Mesh Metric None
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel Part Meshing Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Dimensionally
Rigid Body Behaviour
Reduced
Triangle Surface Mesher Program Controlled
Use Asymmetric Mapped Mesh (Beta) No
Topology Checking Yes
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Statistics
Nodes 75938
Elements 41792

TABLE 2
Model (A4) > Mesh > Mesh Controls
Object Name Edge Sizing Face Sizing
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 168 Edges 62 Faces
Definition
Suppressed No
Type Element Size
Element Size 5.0 mm 15.0 mm
Advanced
Behaviour Soft
Bias Type No Bias
Defeature Size Default

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Fig 5-Longitudinal Hub Stress, SH

Fig 5A-Longitudinal Hub Stress, SH

9
 Fig 6- Radial Stress, SR

Fig 6A- Radial Stress, SR

10
Fig7-Tangential Stress, ST

Fig 7A Tangential hub stress

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5.0 RESULT ANALYSIS

Allowable (MPa) > Manual Result Ansys Results

Longitudinal Hub Stress, SH Min (2.5Sfo & 1.5Sno) 177 59.5 14.46
Radial Stress, SR Sfo 138 14.9 8.32
Tangential Stress, ST Sfo 138 35.3 13.27
SH + SR / 2 Sfo 138 37.2 11.39
SH + ST / 2 Sfo 138 47.4 13.86

TABLE 3 FLANGE ALLOWABLE STRESSES

6.0 CONCLUSION
Comparative study of the stresses in table 3 that obtained from ANSYS work bench software and mathematical
approach illustrates that stress calculated by ANSYS workbench is less than that by mathematical approach
and also less than allowable stresses during the girth flange operation condition. It gives that actual stress
value than the conservative design values in mathematical calculation. It provides the possibility of alter
the design factor and also avoid additional volume, weight and cost of flange materials.

References
ANSYS workbench (version 19.2) [FEA software]
Solid works (2015 version) [3D software]
ASME Boiler & Pressure Vessel Code, Section VIII Div.1
Dennis R. Moss, Pressure Vessel Design Manual Ed 4
ASME Section II Part D Edition 2017.

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