Example-1

Design a loose- e flange with a plain face for a reactor shell with 1.8m outside
diameter and O.O18 1ckness (g0). Other specifications are: Design temperature
-
: 200°c; Design pressure =2.2 MN/m 2; Allowable stress of flange material =120
MN/m 2; Allowable stress of bolting material = 120 MN/m 2; gasket materiaf
Corrugated soft Al metal, asbestos filled [Min. design seating stress (y) = 20
MN/m 2; Gasket factor (m) =2.5; and Min. actual gasket width =10mm]. Ratio of
gasket internal diameter to shell outside diameter is 1.01 ; corrosion allowance =
zero; weld joint efficiency factor = 1.
, Calculate effective gasket seating width
, Calculate minimum bolting area
, Which amongst the following bolts will be u ed for bolting the flange: M
36x3, M39x3, M42x3and M45x3? Give g1 1.41 g0~
, Estimate bolt-circle diameter. v
, Estimate flan e outside diameter after addition of 2 cm assumed gap
between end of bo c1rc ean e dof the fla~-9s
, Estimate various loads and moments under operating as well as bolting-
up conditions
, Estimate flange thickness (Poison'sratio =0.3)
Solution Calculate effective gasket seating width ~

Min gas ket width (N)

d o - di
N = - - =78mm
2
di = 1.01 x 1.8 = 1.818 m
N = 78 mm >10mm

di
00 =
( y - pm
y - p(m +
)½
1)
:. Nnnal = 78 mm; b 0 =
N
2 = 39 mm
Effective gasket width, b
20 - 2.2 X 2.5
do = ( 20 - 2.2(2.5 1) +
)½ x 1.818
b = b 0 ifb 0 < 63mm

= 2.5 ./brJ if b 0 > 6.3 mm

= 1.974 m
:. b = 15.61 mm
NPIEl ONLINE
• llfROORKH CERIIFICAIION COURSE
 Calculate minimum bolting area ~ Allowa ble s tress fo r
Solution bolt n1 ate ria l at
Dia at bottom of gasket load reactio@
Wg = n(G x b) x y d es ign te n1p .
61
G = di + N if b 0 < 6.3 mm = TI (1.94278 X lS.
1000
) X 20

= do - 2b if b 0 > 6.3 mm = 1.0955 MN Allowable s tress

G = 1.974 - 2
x is.61 = 1 94278 Sg = s0 = 120 MN/m2 fo r bolt n1ate ria l
1000 · m at atn1. te mp.
Wo
Ao = ~ = 0.063083 m
2 2 2
H= 1tG P = 1t( 1.94278) x2.2 = 6 522 MN
4 4 .

Hp = n[G x 2b] x mP = 1.048 MN Wg 1.9055

Abe = S =
120
= 0.01588 m 2
w 0 = H + Hp g

= 6.522 + 1.048 = 7.57 MN Am = 0.063 m 2

NPIEL ONLINE
• IITROORKH CERIIFICAIION COURSE
 Which amongst the following bolts will be used for bolting the fl ange:
Solution
M 36 x3, M 39 x3, M 42 x3 and M 45 x3?

g0 = 0.078 m
n= Actual No. of bolts = 92
= 0.02547 m
n8 5 92 x 80
For M 36x 3 C1 = - = 2.343 m
TI TI
Root Area = n (36 - 6) 2 C2 = ID+ 2(g1 + R)
4

= 706.858 mm 2 C2 = 1.8 + 2(0.02549 + 0.05) = 1.951 m

Minimum No. of bolts = Am

C1 - C2 = 0.392 m
Root Area
= 89.127
NPlfl ONLINE
• llfROORKEE CERllflCAIION COURSE
 Which amongst the following bolts will be used for bolting the flange :
M 36 x3, M 39 x3, M 42 x3 and M 45 x3?
For M 39x3

Root area= n (bolt dia - 2t) 2 =855.2986 mm 2

4

Minimum No. of bolts R Am = 73.658

oot a rea
n =Actual no. of bolts=76 ·
n8 5 76 x 86
C1 = TT
- --
TT
- = 2.0805 m
C2 = 1.8 + 2(0.02547 + 0.052) = 1.9549 m
C1 - C2 = 0.1256 m
NPlfl ONLINE
• llfROOIKEE CERIIFICAIION COURSE
Solution Which amongst the following bolts will be used for bolting the flange :
M 36 x3, M 39 x3, M 42 x3 and M 45 x3?

For~ 4~3
Root Area= 1T ( 42 - 6) 2 = 1017.876 mm~
4

Minimum No. of bolts=61.89

n = Actual no. of bolts= 64
64 X 91
C1 = - - - = 1.854 m
lT

C2 = 1.8 + 2(0.025471 + 0.055) = 1.961 m

C1 - C2 = -0.107 m

NPlfl ONLINE
• IITROORKEE CERTIFICAIION COURSE
 Which amongst the following bolts will be used for bolting the flange:
M 36 x3, M 39 x3, M 42 x3 and M 45x3?

For~
Root area =1194.59 mm 2
Minimum No. of bolts =52. 74
Actua l No. of bolts =56 ✓-
56 X 96
C1 = - - - = 1.711 m
TT

C2 = 1.8 + 2(0.02547 + 0.057) = 1.965 m

C1 - C2 = - 0.254 m

NPIEl ONLINE
• IITROORKH CER1IflCAIION COURSE
Solution Which amongst the following bolts will be used for bolting the flange:
M 36 x3, M 39 x3, M 42 x3 and M 45 x3?

Bolt
M 36 x3 2.343 1.951 0.392
M 39 x3 2.0805 1.9549
M 42 x3 1.854 1.961 -0.107
M 45 x3 1.711 1.965 -0.254

Since for M 39x3 C1 - C2 is least and positive

:. M 39 x3 will be used for bolting the flange

NPIEl O NLI NE
• IITROORKH CERIIF IC AIION COURSE
Solution Estimate bolt-circle diameter and Flange Outside Diameter

Bolt circle diameter C

C = C2 for the bolt for which difference is positive and minimum
C =1.9549 m
Flange Outside Diameter
A = C + 2 x bolt radius + 0.04
39
= 1.9549 + -1000 + 0.04 = 2.0339 m

NPIEl ONLINE
• llfROORKEE CERIIFICAIION COURSE
 Estimate various loads and moments under operating as
well as bolting-up condition_s_
- (C - 8)
nB 2 V al=
W1 = 4 P = 5.598 MN 2
1.9 549 - 1.8
TT
W2 =H- W1 = -4 ( G2 - B2 ) P 2
= 0.07745 m 9,--i I -:-rt
= 6.522 - 5.598 = 0.924 MN -f
~ (C-G) Wo
h
W 3 = Hp = 1.048 MN a3 =
2 _J_
WO = W2 + W3 + W3
= 7.57 MN -
(C - G)
2
= 0.00606 m e
~L
C
a, -
Solution Estimate various loads and moments under operating as
well as bolting-up conditions

(a1 + a3) ✓ 0.065 + 0.063

a2 =
2
= 0.041755 m w = _____ x 120
2
M0 = W1 a 1 + W2 a 2 + W3 a 3 = 7.68
= 0.4785 MNm
Mg = 7.68 X 0.00606
Bolting - up conditions
= 0.054654 MNm
Am +Ab
W= Sg M = Max of M 0 and Mg
2
Ab = No. of actual bolt x Root Area = 0.4785 MNm
= 0.065 m 2
Solution Estimate flange thickness (Poison's ratio =0.3)
MN t2 = 0.4785 x l _
Assume cf= 1, Sfo = 120 -2 , µ
m
= 0.3 1.8x120 X 15.9066 - 0.1877 m

0.080809
(0.078 + 0.1877) = 0 ·w~55133
k =A= 2.0339 = 1.13
8 1.8
0.955 k 2 log k
t = 0.139382463
Y= k-l [(1 - µ) + (1 + µ)4.605 k2 _
1
] CF = 0.609548193
t = 0.14655 7037
y = 0.955 [0.7 + (1.3 X 4.605) 1.132 log 1.1 3] CF = 0.599731647
0. 13 1. 1 32_ 1
t = 0 .145372124
= 15.9066 CF = 0.60132023
nC TT x 1.9549 t = 0.145564529
Bs = -;- = = 80.509 mm CF = 0.601061418
76
0.1455332
 A loose type flange is used toloin two parts of a shell with OD as 0.8 m. Design this
flange for following specifications: ----·
Flange face: Plain face; Design pressure (g)=2.S MN/m 2; Design temperature=400°C;
Allowable stress of shell material=120 MN/m 2 ; Allowable stress of flange material
at design temperature=130 MN/m 2; Bolts are made with IS:2002-1962 2A material;
Gasket material: soft aluminum solid flat metal; Ratio of gasket internal dia. to Shell
outside dia.=1.02; Corrosion allowance=0; Weld joint efficiency factor=l;
gn=0.0lSm; g 1 =1.415 gn, µ=0.3.
a. Calculate effective gasket seating width.
b. Select the suitable bolt for the flange: M 33x2, M 36x3, M 4Sx3, M 24x2?
C. Estimate flange outside diameter.
d. Estimate flange thickness.

NPTH O NLI NE
• IIT ROORK EE CERTIIIC AIION COURSE
 Do -- 0.8 ·m
Design pressure (g) - 2.5 MN/ m 2
Allowable stress of shell _.. -- 120 MN/ m 2 67 MN
Allowable stress of fl ange = 130 MN/ m2
Allowable stress of bolt at atm temp Q
Allowable stress of bolt at des t emp --
96.10510N/ m 2
72.56921 MN/ m 2
9.8
7.4
,/j ~ "'-
')11N'I

y - 61 MN/ m 2
m -- 4
di/Do -- l .02
J - 1
go -- 0.015 m
~l - 0.3

NPlfl ONLINE
• IITROORKIEE CERIIFICAIION COURSE
 ?lJl~U~ffl
Calculate effective gasket seating width

di
do/di
-
--
0.816
1.025449361
m d0 ( y- pm
d, = y - p(m + l)
r
do - 0.836766678 m
Min gasket w idth -- 0.010383339 >6mm
Min gasket width - 0.010383339 m
Actua l gasket width (N) - 0.010383339 m
Act ual do=di+2N -- 0.836766678 m
Basic gasket width (b0 ) -- 0.00519167
Effective gasket width (b) -- 0.00519167 m b=b0 if b0 $ 6.3 mm
G= d.+N
I
- 0.826383339 m

NPIEl ONLINE
• IITROORKH CERIIFI C AIION COURSE
.Solution Select the suitable bolt for the flange: M 33x2, M 36x3, M '- .x ,
M 24x2?
H - 1.34021 MN
Hp -- 0.26943 MN ✓
Wo=H+Hp -- 1.60964 MN Ao -- 72.569
W g=pGby - 0.82177 MN Ag -- 96.105
Am =M ax(Ao, Ag) -- 0.022 181 m2
.
.,,
I/Size Root area, m 2 Min. bolt Act. bolt R Bs C, c., C1 -C.,
I 33
36
"
2\ 0.000660185
3 0.0007065
33.6)
31.4 l,
36
32 '7
0.047
0.05
0.077
0.08
0.882356 0.93645 -0.05409
0.814874 0.94245 -0.12758
45 3 0.001193985 18.6 20 0.057 0.096 0.611155 0.95645 -0.34529
\ ~ 24 2/ 0.000314 70.6 72 0.035 0.075 1.718875 0.91245 0.806425
.....,_ /
✓ /

NPTEl O NLI NE
• IITROOIK EE CERTIF IC ATION COURSE
 Estimate flange outside diameter

Size Root area, m 2 Min. bolt Act. bolt R Bs (1 c., C1-C.,

33 2 0.000660185 33.6 36 0.047 0.077 0.882356 0.93645 -0.05409
36 3 0.0007065 31 .4 32 0.05 0.08 0.814874 0.94245 -0.12758
45 3 0.001193985 18.6 20 0.057 0.096 0.611155 0.95645 -0.34529
( ~ 24 Z) 0.000314 70.6 72 0.035 0.075 1.718875 /{f.91245) 0.806425
/ ~

Fla nge diam et er = A = 0.95645 m =0.91245+(24/1000)+0.02

NPIEL ONLINE
• llfROORKH CERIIFICAIION COURSE
Solution Estimate flange thickness

B=Do -- 0 .8 m
Wl -- 1.256
W 2=H-W 1 -- 0.084209743 K=A/ B - 1.1955625
W 3 =W 0 -H - 0 .269431423 y -- 10.96771161
a1=(C- B)/ 2 -- 0 .056225 --
CF 1
a3 =(C-G)/ 2 -- 0.04303333 t - 0.098829541 m
a 2=(a 1+a3 )/ 2 -- 0.049629165 -- 0.089534156
Bs
M o=W i a1+W 2a2+w3a3 -- 0.086392391 - - CF - 0.723957189
Ab - 0 .022608 t -- 0.084089781 m
w -- 2.152216317
M g=Wa 3 -- 0 .092617036 _,/
Controlling M -- @:092617030 MNm

NPIEl ONLINE
• IITROORKEE CERIIFICAIION COURSE