Report 96641 November 27, 1996 ‘Mechanical Engineering Consulting Services and Software Analysis of 4-1/16”- 5000 psi API 6B Flange with External Bending and Tension Loads for Pikotek Inc. Lakewood, CO ABSTRACT: An API 6B 4-1/16" 5000 psi flange was analyzed based on the use of a Pikotck VCS gasket, with external bending moments and tension applied in addition to the internal pressure. Stresses were found to be within API 6A allowable limits, A maximum bending moment of 50,746 ft-bf or 68,800 N-m can be applied to the flange when preloaded to API recomended torques. BY x. 7 "E pare _s//ex/ag 1 P.O. BOX 925393 * HOUSTON, TEXAS 77292 * PHONE (713) 688-0767 * FAX (713) 688-7610Report 96641 ‘November 27, 1996 BACKGROUND ‘The flanges in question are API Type 6B 4-1/16” 5000 psi flanges, with the folowing combination of pressure, tension, and bending moments applied: Prossure: 143.9 bar 2087 psi Bending: 13754Nem 10145 RIDE Tension: 4980N 1120 Ibe ‘The materials of the flanges and studs are: Flange A ASTM A182-F51 90,000 psi min. tensile 65,000 psi min. yield Flange B API 60K 85,000 psi min. tensile 60,000 psi min. yield Studs ASTM A193-B7 125,000 psi min, tensile 105,000 psi min. yield Design pressure is 5000 psi. Operating temperature is 77° C (170° F). METHODS AND ASSUMPTIONS ‘The flanges were analyzed based on the methods of the M. W. Kellogg publication, Design of Piping ‘Systems (see Attachment B). The method in this reference involves calculating an equivalent pressure which takes into account the effect ofthe tension and bending moment on the flange, then analyzing the flange using the standard ASME method (ASME Code, Section VIII, Division 1, Appendix 2). ‘The ASME flange calculations were performed using the BASIC FLANGE computer program. This program permits the use of API 6A allowable stresses as an alternative to the more conservative ASME. allowables. API allowables were used for the analysis. Flange allowable stresses were based on the API 60K material, which is slightly weaker than the mating Duplex Stainless Stee! flange. In addition, the load on the bolting was calculated based on the equivalent tension method, using the bolt circle diameter as the effective diameter of the bolt forces. This method assumes the bolt loading is distributed uniformly around the bolt circle rather than concentrated at the bolt centers, but is fairly accurate for eight or more bolts. This calculation assumed that the bolts were initially tensioned to the values recommended in API Specification 6A Appendix D. RESULTS Attachment A shows the calculation of the limiting moment based on bolt stesses. ‘This moment was higher than the moment calculated based on flange strength; therefore, the bolting is not the limiting clement with respect to bending, Amaximum moment of 50,746 ft-lbf (68,800 N-m) can be applied to the flange bolting. ‘The equivalent pressure for the pressure plus tension plus bending analysis is calculated in Attachment B. ‘The combined effect of the loading on the flange body is equivalent to an internal pressure of 5869 psi. ‘The flange was analyzed for both the design pressure case of 5000 psi (run 96641A.DAT) and 5869 psi (run 96641B,DAT). ‘The highest stress at working pressure, relative to the allowable stress, was the flange ‘tangential stress, ‘These stresses forthe two cases are shown on Attachment C. Attachment C then calculates the highest equivalent pressure that this flange could withstand before ‘exceeding the allowable stress. ‘The pressure and tension loading is then decucted from this total, leavingReport 96641 November 27, 1996 that portion of the equivalent pressure which represents the bending load. Converting this to a bending ‘moment yielded a maximum bending moment of 36153 f-Ibf or 49015 N-m, CONCLUSIONS ‘The flange/gasket system will withstand the loading required by this application while keeping stresses ‘well within API 6A limits. The maximum bending moment that can be applied to this flange is 36153 f- Ibf or 49015 Nem,On-Line Resources Report 96641 Attachment A Page At Flange Bending Moment Effect on Bolt Loading - A193-B7 Studs Input Data Bolt Root Area Number of Bolts Bolt Circle Diameter Bolt Yield Strength Axial Tension Calculated Data Total Bolt Load Limit Preload Force Available Force for Bending at Opsi Maximum, Bending Moment 96641. MCD - 11/27/96 4-1/16" - 5000 API 6B Flange Ay =0.9294in? Ny=8 D'=950in Y¥ = 105000 psi T= 112046 F max =O8F AGN Y OSAYNEY 4-114" - BUN-2 F max 76476994100 Fy =390180-10F Fy =256399¢Ibf (M = 608947 sin Tot M = 50746 -fIbE M = 68800 -newton'mOn-Line Resources Report 96641 Attachment B Flange Bending and Tension Capacity by the Equivalent Pressure Method Reference: Desian of Piping Systems, M. W. Kellogg Co., John Wiley and Sons, New York, 1956, p. 78 Units bar = 10%. 2et00 mn? Input Data Operating Pressure Py = 3.9 bar 2087 -psi 6 Diameter G=5.496.in Bending Moment M =13754-newton-m M=10145-RbF ‘Axial Tension TT =4980-newion T= 112040 Calculated Data 4 Equivalent Pressure eu +6 Total Pressure P=PytPe P= 404.6-bar 9664IB. MCD - 11/27/96On-Line Resources. Report 96641 Determination of Maximum Allowable Bending Moment. Input Data Rated Pressure Operating Conditions Equivalent Pressure Stress at Py Stress at P, Allowable Stress Operating Moment Operating Force Operating Pressure G Diameter Calculated Data Max. Equivalent Pressure Portion Due to Pressure and Applied Tension Portion available for bending moment Bending Moment 9664IC. MCD - 11/27/98 Spy = 40000-psi M = 10145-ftIbE T= 120dbF Py = 2087 psi @ =5.496.in P nay * 15443 “psi P tare = 2134 psi Py = 13309 psi 16 M=36153 fbf M=49015 mewton-m Attachment C96641A.DAT API Type 6B 4-1/16 - 5000 psi Flange Page 1 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:03:59 BASIC FLANGE FLANGE ANALYSIS PROGRAM RESULTS The methods used in calculating the flange stresses, as well as much of the nomenclature, are found in the ASME Boiler and Pressure Vessel Code, Section VIII, Division 2, Appendix 2 All units in this report’are in the inch/pound system. RUN DATE +: 11-27-1996 Title : API Type 6B 4~1/16 - 5000 psi Flange For : Pikotek W is set to 0.5 (Am+Ab) Sa (ASME Default! API 6A/16A Allowable Stresses API 6A Test Pressure Allowables Program Option 1 : Progran Option 2 Program Option 3: Analyzed by E_ vate _1//27, y Checked by Date Bee INPUT DATA Data were last saved on 11-27-1996 11:03:59 1. Flange Bore ‘B' [in] 4.0600 2. Flange oD [in] = 12.2500 3. Bolt circle {in} = 9.5000 4. Bolt Nominal Diameter [in] = 112500 5. Number of Bolts = 8 6. Flange Thickness [in] = 2.1200 7. Hub Length {in} 2.7500 8. Hub major diameter tin] 623800 9! Hub minor diameter fin] 4.5000 10. Hub Major Thickness ‘Cin} 1.1600 11. Hub Minor Thickness tin) 0.2200 12. Gasket Diameter {in} 5.4960 13. Gasket effective width ‘bot [in] = 0.4810 14. Gskt Matl # = 4 -- Pikotek vcs 15. Flange Material File = API-60K 17. Bolt Material File A193-B7 18: Operating Temperature ‘TOp' [‘F ] 200 19: Design Working Pressure | 'P' [psi] 5,000 20: Hydrostatic TEST Pressure'TP' [psi] 7,500 21: Flange Young's Modulus —_'E' [psi] 30,000,000 22. Flange type: ap, ntegral, 6B = I “- Integral Pikotek 25. Company Name API Type 6B 4-1/16 - 5000 psi Flange 26. Report Title BASIC FLANGE Version 1.03 - Dec. 19969664TA.DAT API Type 6B 4-1/16 - 5000 psi Flange Page 2 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:0 259 CALCULATION RESULTS Jnbidodddobebiintie® FLANGE FACTORS }}tHur EEE RE Factor 0.945093 Factor 4.272727 Factor 3,131.2373 Factor 2.909768 Factor 1000000; was -0.143535 B sub 1 5.220000 Factor 0.454119 Factor 0.013224 Factor 301724138 Factor 120139407 Factor 2.04210524 Factor 185832012 Factor 124679946 Gasket factor m 0.0000 Min Design Seating Stress 12,500 Basic Gasket Seating Width bo 0.4810 Effec. Gasket Seating Width b = 0.3468 Factord == 7.0640 Factor e = 0.480502 Factor L = 3.029099 FEE ESE ISIC IG ASIII IA IOI OS III IAI II IAI Job ddodnonieeeiiniieee MOMENT ARMS iibnnE bono iia Moment arm HD 2.1400 in Moment arm HG 2.0020 in Moment arm HT 2.3610 in TEESE IE EGO ASSIS OO ATIC ISITE II II III III duakwekAR FLANGE AND BOLTING MATERIALS *##44848 ARIE FLANGE MATERIAL: API-60K DESCRIPTION: API 60K Alloy Steel BOLTING MATERIAL: A193-B7 DESCRIPTION: A193 Grade B7 High Strength Alloy Steel Bolting Ma9664IA.DAT API Type 6B 4~1/16 - 5000 psi Flange Page 3 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:03:59 CACULATIONS BASED ON[ WORKING PRESSURE] WORKING PRESSURE ALLOW. BOLT STRESS TOTAL HYDRO FORCE HYDRO END FORCE DIFFERENCE H-HD Top dodo BOLT MIN. OPERATING BOLT LOAD MIN. GASKET SEATING BOLT LOAD Wwm2 REQ'D BOLT AREA FOR OPERATING Am1 P Sa ALLOW. FLANGE STRESS Sn deeeeRHOCER FOL AN GE H HD HT GASKET RETAIN'G LOAD HP = 5,000 ‘TEMPERATURE 200 deg F 52,500 40,000 FORCE S tettaanceaneee 118,619 1b 64,731 1b 53,888 1b 0 1b LOADS *kttEAAARRRREARER Wm 118,619 74,843 2.259404 REQ'D GASKET SEATING BOLT AREA. Am2 = 1.425574 MINIMUM REQUIRED BOLT AREA ACTUAL BOLT AREA NUMBER OF BOLTS AND SIZE ARE OK -- 2.259404 7.99763 ‘*#*%* FLANGE MOMENTS BASED ON OPERATING CONDITIONS ***** FLANGE BOLT LOAD GASKET LOAD MOMENT OF HD MOMENT OF HG MOMENT OF HT TOTAL MOMENT W HG MD MG MT. Mo 118,619 0 138,524 0 127,229 265,753 ‘##*%* FLANGE STRESSES BASED ON OPERATING CONDITIONS *#++#*% HUB LONGITUDINAL STRESS FLANGE RADIAL STRESS FLANGE TANGENTIAL STRESS [SH+SR]/2 [SH+ST]/2 SH SR ST = 12,948 Vs 40,000 - OK - OK OK OK OK 12,490 VS 60,000 11/322 vs 40,000 hit 11,906 VS 40,000 12,719 VS 40,00096647A.DAT API Type 6B 4-1/16 ~ 5000 psi Flange Page 4 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:03:59 ###** ALLOWABLE STRESSES FOR GASKET SEATING CONDITION ***** ALLOW. BOLT STRESS Sa = 52,500 ALLOW. FLANGE STRESS Sn. 40,000 #*x**xe* FLANGE MOMENTS BASED ON GASKET SEATING LOAD +###** FLANGE BOLT LOAD wos 269,247 TOTAL FLANGE MOMENT Mo = 539,033 xxk4%% FLANGE STRESSES BASED ON GASKET SEATING LOAD *####* HUB LONGITUDINAL STRESS SH = 25,335 VS OK -- FLANGE RADIAL STRESS SR = 22,965 VS OK - FLANGE TANGENTIAL STRESS ST = 26,263 VS OK -- [SH+SR]/2 24,150 VS OK -- (SH+ST]/2 25,799 VS OK --96641A. DAT API Type 6B 4-1/16 - 5000 psi Flange Page 5 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:03:59 CACULATIONS BASED ON[ TEST PRESSURE] TEST PRESSURE Tr = 7,500 ALLOW. BOLT STRESS AT TEST PRESS. Sa 87,150 ALLOW. FLANGE STRESS AT TEST PRESS. Sn 49,800 aeekkkaaeeeeeee FLANGE FOR CE S tekkeeieeneeiie ‘TOTAL HYDRO FORCE H 177,928 1b HYDRO END FORCE HD 97,096 1b DIFFERENCE H-HD Hr 80,832 1b GASKET RETAIN'G LOAD HP = 0 lb teekeketeReRREE BOL T LOAD S HiHHE SEE MIN. TEST PRESSURE BOLT LOAD = wml = 177,928 MINIMUM REQUIRED BOLT AREA An 2.041630 ACTUAL BOLT AREA Ab = 7.997637 - NUMBER OF BOLTS AND SIZE ARE OK -- = ‘#e**% PLANGE MOMENTS BASED ON TEST CONDITIONS *#*** FLANGE BOLT LOAD W 177,928 GASKET LOAD HG 0 MOMENT OF HD MD 207,786 MOMENT OF HG MG 0 MOMENT OF HT MT 190,844 TOTAL MOMENT Mo = 398,630 ‘##*%% FLANGE STRESSES BASED ON TEST CONDITIONS ***##* HUB LONGITUDINAL STRESS SH = 18,736 VS 74,700 FLANGE RADIAL STRESS SR = 16,983 VS 49,800 — FLANGE TANGENTIAL STRESS ST = 19,422 VS 49,800 = [SH+SR]/2 17,859 VS 49,800 — [SH+ST]/2 19,079 VS 49,80096641B.DAT API Type 6B 4-1/16 - 5000 psi Flange Page 1 BASIC FLANGE 1.0 Pikotek 11-27-1996 11: BASIC FLANGE FLANGE ANALYSIS PROGRAM RESULTS The methods used in calculating the flange stresses, as well as much of the nomenclature, are found in the ASME Boiler and Pressure Vessel Code, Section VIII, Division 2, Appendix 2. All units in this report are in the inch/pound system. RUN DATE : 11-27-1996 Title : API Type 6B 4-1/16 - 5000 psi Flange For Pikotek 1 2 -- Wis set to 0.5 (Am+Ab) Sa (ASME Default) -- API 6A/16A Allowable Stresses -- API 6A Test Pressure Allowables Program Option 1 Program option 2 Program option 3 Analyzed by Lin VL Ah, (7 pate _y//b hes Date Checked by INPUT DATA Data were last saved on 11-27-1996 1: 1. Flange Bore 'B 4.0600 2. Flange oD ‘at 12.2500 3. Bolt circle sa ‘9.5000 4. Bolt Nominal Diameter ‘Dt 1.2500 5. Number of Bolts ‘nt 8 6. Flange Thickness ‘tt 2.1200 7. Hub Length tht 2.7500 8. Hub major diameter ‘xt 6.3800 9. Hub minor diameter x2! 4.5000 10. Hub Major Thickness tgl 1.1600 11. Hub Minor Thickness "go! 0.2200 12. Gasket Diameter ‘ge 5.4960 13. Gasket effective width ‘bo! 0.4810 14. Gskt Matl # = 4 -- Pikotek Vcs 15: Flange Material File = API-60K 17. Bolt Material File A193-B7 18: Operating Temperature 'Top' [°F ] 200 19: Design Working Pressure 'P' [psi] 5,869 20. Hydrostatic TEST Pressure'TP' [psi] 7,500 21. Flange Young's Modulus —'E' [psi] 30,000,000 22. Flange type: ap, ntegral, 6B = I ~~ Integral 25. Company Name = Pikotek 26. Report Title = API Type 6B 4~1/16 - 5000 psi Flange BASIC FLANGE Version 1.03 - Dec. 199696641B. DAT API Type 6B 4-1/16 - 5000 psi Flange Page 2 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:07:56 CALCULATION RESULTS Jedd oieneonbbeeedo: FLANGE FACTORS ii aurora ae Factor ho 0.945093, Factor A 4.272727 Factor C 3,131.2373 Factor h/ho 2.909768 Factor f 1.000000; was -0.143535 B sub 1 5.220000 Factor F 0.454119 Factor V 0.013224 Factor K 3.01724138 Factor T 1:20139407 Factor U 2.04210524 Factor ¥ 1.85832012 Factor Z 1.24679946 Gasket factor n 0.0000 Min Design Seating Stress y 12,500 Basic Gasket Seating Width bo 0.4810 Effec. Gasket Seating Width b = 0.3468 Factor d = = 7.0640 Factor e 0.480502 Factor L = 3.029099 JOE O TOBA I III III IAI III TTI I I III II IIIT JetnaduHnEoeeoEHioEE MOMENT ARMS tusdnbnnodHnnnEE Moment arm HD 2.1400 in Moment arm HG 220020 in Moment arm HT 2.3610 in JESSIE STO III ITO IOI III TTI I III weceieeeeRRK FLANGE AND BOLTING MATERIALS *###ex# 8H RHH FLANGE MATERIAL: API-60K DESCRIPTION: API 60K Alloy Steel BOLTING MATERIAL: A193-B7 DESCRIPTION: A193 Grade B7 High Strength Alloy Steel Bolting Ma96641B.DaAT API Type 6B 4-1/16 - 5000 psi Flange Page 3 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:07:56 CACULATIONS BASED ON[ WORKING PRESSURE] WORKING PRESSURE P 5,869 TEMPERATURE 200 deg F ALLOW. BOLT STRESS Sa 52,500 ALLOW. FLANGE STRESS Sn = 40,000 aetkkkaneeeeeee PLAN GE FOR CE S ##tttteeeeeaian TOTAL HYDRO FORCE H 139,235 1b HYDRO END FORCE HD 75,981 1b DIFFERENCE H-HD HT 63,253 1b GASKET RETAIN'G LOAD HP 0 1b tekkeeeER RRR BOLT LOADS skktteeeHREEEEE ER MIN. OPERATING BOLT LOAD wml = 139,235 MIN. GASKET SEATING BOLT LOAD Wm2 74,843 REQ'D BOLT AREA FOR OPERATING Am1 2.652089 REQ'D GASKET SEATING BOLT AREA. Am2 1.425574 MINIMUM REQUIRED BOLT AREA An 2.652089 7.99763 ACTUAL BOLT AREA Ab s------ NUMBER OF BOLTS AND SIZE ARE OK - ‘#e*** FLANGE MOMENTS BASED ON OPERATING CONDITIONS **#*# FLANGE BOLT LOAD W 139,235 GASKET LOAD HG 0 MOMENT OF HD MD 162,600 MOMENT OF HG MG 0 MOMENT OF HT MT = 149,341 TOTAL MOMENT Mo 311,941 ‘4#x*%% FLANGE STRESSES BASED ON OPERATING CONDITIONS *###** HUB LONGITUDINAL STRESS SH = 14,661 VS 60,000 - oK FLANGE RADIAL STRESS SR = 13,290 VS 40,000 -- OK FLANGE TANGENTIAL STRESS ST = 15,199 VS 40,000 oK 13,976 VS 40,000 14/930 VS 40,000 OK OK [SH+SR]/2 (sH+sT]/296641B. DAT API Type 6B 4~1/16 - 5000 psi Flange Page 4 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:07:56 ‘#k%*% ALLOWABLE STRESSES FOR GASKET SEATING CONDITION **#** ALLOW. BOLT STRESS Sa 52,500 ALLOW. FLANGE STRESS Sn 40,000 ‘+##4e* FLANGE MOMENTS BASED ON GASKET SEATING LOAD *#+#+4 FLANGE BOLT LOAD W 279,555 TOTAL FLANGE MOMENT Mo 559,670 ‘#k44%% FLANGE STRESSES BASED ON GASKET SEATING LOAD ***#4* HUB LONGITUDINAL STRESS SH = 26,305 VS 60,000 ~ oK FLANGE RADIAL STRESS SR = 23,844 VS 40,000 oK FLANGE TANGENTIAL STRESS ST = 27,269 VS 40,000 oK [SH+SR]/2 (SH#ST]/2 25,074 VS 40,000 26,787 VS 40,000 OK oK96641B. DAT API Type 6B 41/16 ~ 5000 psi Flange Page 5 BASIC FLANGE 1.0 Pikotek 11-27-1996 11:07:56 CACULATIONS BASED ON[ TEST PRESSURE] TEST PRESSURE T = 7,500 ALLOW. BOLT STRESS AT TEST PRESS. Sa 87,150 ALLOW. FLANGE STRESS AT TEST PRESS. Sn 49,800 detkkkaaeeeeeee FLANGE FORCE S *#eeankeeeaeees TOTAL HYDRO FORCE H = 177,928 1b HYDRO END FORCE HD = 97,096 1b DIFFERENCE H-HD HT 80,832 1b GASKET RETAIN'G LOAD HP 0 1b dtttheeeeeeee BOLT LOADS *kttteeeeeaaaaae MIN. TEST PRESSURE BOLT LOAD = wml = 177,928 MINIMUM REQUIRED BOLT AREA an = 2.041630 ACTUAL BOLT AREA Ab = 7.99763 NUMBER OF BOLTS AND SIZE ARE OK -- #4 FLANGE MOMENTS BASED ON TEST CONDITIONS *#### FLANGE BOLT LOAD W 177,928 GASKET LOAD HG 0 MOMENT OF HD uD 207,786 MOMENT OF HG MG 0 MOMENT OF HT MT = 190,844 TOTAL MOMENT Mo = 398,630 ##*%%* FLANGE STRESSES BASED ON TEST CONDITIONS *###*% HUB LONGITUDINAL STRESS SH = 18,736 VS 74,700 -- FLANGE RADIAL STRESS SR = 16,983 VS 49,800 FLANGE TANGENTIAL STRESS ST = 19,422 VS 49,800 [SH+SR]/2 = 17/859 VS 49,800 [SH+ST]/2 19,079 VS 49,800 here