BOLTED FLANGED CONNECTIONS FOR NON-CIRCULAR PRESSURE VESSELS AE. Blach, Associate Professor Concordia University Montreal, Canada ABSTRACT ‘The ASME Bolter and Pressure Vessel Code contains rules for non-circular pressure vessels of unretnforced and reinforced construction. These rules are given in Section VIII, Division 1, Appendix 13, and cover the Sides, reinforcing ribs,” and end plates of such ves- sels. For bolted flanged’ connections of such non-circu- lar pressure vessels, which are used extensively in industry (cyclone inlets, chutes and feeders, etc), no design rules are available at present. This paper describes two design methods for non- circular flanges which are used at present by pressure Vessel designers and compares calculated values with data from strain gage measurements on rectangular pres~ sure vessels and with results from finite element cal- cutattons. INTRODUCTION Our modern chemical and process industries would not exist in the form known to us if the bolted flanged Connection were not available as a conveniant means of Jotning together the various pieces of equipment which imake up such a plant. Flanges. constitute a very impor~ tant part of all pressure containing apparatus. Without Flanges, the mafority of modern process equipment would not exist in the form known to us. Due to the favoura~ ble circular geonetry employed in most pressure vessels. or piping systems, most of the flanges used are cireu= Var flanges, n'a variety of pressure classes and facing types. There are, however, many applications in which cfrcular pressure containers or conduits cannot be used for various reasons. For example the inlet nozzles on cyclones are usually of rectangular. shape as are. the Wood chip chutes on pulp digesters; the headers on Steam boilers are normally square and the inlet and outlet headers of air-cooled heat exchangers are. rect= angular. For such non-etreular cross-sections, flanges are often reqifred, be st for access or for connection to other equipment. 97 Bolted flanged connections, being part of pressure containing systems, are governed by the various pres- sure vessel codes existing in all industrialized coun- tries, for example the ASHE Botler and Pressure Vessel Code TAT. The ASME Code contains extensive rules for the design of pressure vessels and pressure vessel compo= nents, including rules for non-circular pressure ves- Sels," but no rules for non-circular bolted flanged Connections. Two extensive literature searches of el= ted flanged connection publications, one by Blach & Bazergut (21, one by Cassidy & Kim [3], have shown that very little has been published on this subject. The only type of non-circular bated flanged connection linich has received some attention seems to be the Flanged joint in split steam turbine housings, not really representative of the majority of non-circular ‘Flanges ‘used. This paper discusses some of the approximate de sign methods presently in use and compares numerical results from ‘these methods with experimental values obtained from strain gage measurements and with finite element calculations. Numerical sample calculations for two approximate methods are included and results are discussed. APPROXIMATE DESIGN METHODS ‘There are several approximate design methods which can be used in the design of non-circular bolted Flan- ged connections. Two of ‘these methods, often used ty Dressure vessel designers, are discussed below. One fs based on an equivalent circular Flange and may be used quite safely in the case of square or nearly square flanges [4], the other uses a combination of frane bending analysis and of bending of an infinitely Tong Flanged section in a perpendicular plane with respect to the frame [5]. (+) Numbers in square brackets [_] indicate references Listed at the end of this report.Equivalent Circular Flange Method This method 15, similar in approach tot proce- dure used ‘in the ASME Code, Section VIII, Division 1, Article US-34 [1], for the design of non-circular flat covers. In the Code, a factor Z is defined which re- Jates a flat cover of rectangular shape to a circular one. The factor Z is given by Z- 34- S8¢ D with the Timitatfon that 2 does not need to be larger than two and one half (2.5). The square root of this factor $s used as a multiplier of the small side of the rectangular cover to obtain an equivalent diameter to be used in the thickness formula given, a For a welded flat cover, this approach yields a cover thickness on the safe side, as can easily be seen by comparing square and. rectangular cover stress fac tors with equivalent circular cover factors. In the case of a rectangular cover with Tittle fixation at the im (thin sheTl, thick cover], from Roark & Young [6], the factor (3 in (by S-Bp(z) (2) is .287 for a square plate and approaches .750 for Tong rectangular plate with a/b> 4. Using the Code formula For rectangular plates, 4 comparison can be nade with the factors given in [6]. Equating the stres~ ses from both, [1] and [6], 2) /a\ Ce s)e = ee (z Zee) it can be seen that the factors (3 and CZ should have ‘the same values. In fact, using the Code constant ¢ = Ss and the apbrepriee’ values for eth prowict cl 43 always munerically larger than B, hence the Code Formulas yield results on the safe stde. a In this design method, the square root of 2 is used a5 a multiplier for the small side of the rect angular pressure vessel and thus an equivalent circular shape 1s obtained. Any obround or rectangular Flange an then simply de designed or analysed as equivalent. Circular flange, and all flange design Code rules per Appendix 2 or Appendix Y of the ASME Code [1] are applicable without modification. In the case of full face goskets, often used with rectangular Flanges (see Fig. 1), no ASME Code Rules exist at present. Referen- ‘ces [7) and [8] describe Flange design methods for full Face gasketed bolted flanged connections. An example for the application of this method is shown in Fig. 2, where the equivalent circular flange js superimposed over a rectangular flange of 200 x 200, mma (@ x 12 inch). In this case, the equivalent inside Glaneter ts calculated o (24200). yg 300 B= b[Z'= (200){1.8 = 268mm 34- 98 Bolt cfrele and outside diameters are then ob- tained by adding to the equivalent inside diameter the actual bolt location distance ané the flange width, respectively. LL “yl Ring Gasket ASME" Code App.2, 1-1 O-Ring Gasket ASME Code App.Y Full Face Gasket Mo ASHE Code Rules Fig. 1, Gasket Types The equivalent circular Flange method has untiT recently not been verified. Preliminary test results Feported in [9] seem to indicate that this method yields safely designed rectangular flanges if the Tength to width ratio 1s close to unity, that is, for almost square” rectangular geometries. For long ‘rect angular flanges with length to width ratios of over 2, however, there 4s no wore resemblance. in the behaviour of the rectangular flange when compared with a circular Flange. This fact is acknowledged by designers, and 2 Tength to width ratio limit of 1.5 {5 usually applied. This method can be used only for Flanges on un- reinforced pressure vessels. For rib-reinforced rectan- gular vessels, heavy frame bending stresses must also be accommodated by the flanges, hence the method is not recommended. For unrefnferced vessels, frame. sending Stesses are absorbed in the vessel walls and do not greatly influence the flange stresses. ia ae -200 138} _— 300 eae Fig. 2, Equivalent Circular FlangeFrame Bending Flange Design Method The equivalent circular flange method discussed in the previous article, in addition to length-to-width ratio limitations, 1s" applicable only for un-reinforced hon-circular pressure vessels where. the frome bending Stresses are fully absorbed by the pressure vessel side plates. A large percentage of non-circular pressure ves- sels, however, is of the reinforced type as shown in Fig.” 3. In this case, the flange mist also act as stiffener for the vessel side plates, in addition to Providing a tight seal between compofents. Thus, such Flanges have to resist frame bending stresses in a Blane perpendicular to the vessel axis, in addition to Flange bending stresses in planes parallel to this axis The two stresses, of course, are the result of biaxial bending and thus should not really be sepoe fated: however, nost designers ad these two stresses in order to conpute a sate Tange thickness: Prelieina: ry test results reported in £3] show that this proce= Give yields ange designs’ on the sae ‘side. (STIFFENER é } “seu CrLaNce Fig. 3, Reinforced Non-Circular Pressure Vessel Frane Bending Stresses For rectangular flanges of uniform thickness, the frame bending stresses can be found from structural analysis. For rectangular frames. of Uniform cross. sec~ ‘ion (flanges of uniform width], the corner moments. are given by wr bP 4 8? 12 @se ‘and the monents at the center of the Tong span My a (5) awe Ms» “3 - Ma Where the 1ength dimensions €, and €x are taken between the centroids of the flange sections, or of the flange: shell Junction if part of the connecting shell ts included in the calculations (See Fig. 4). For flanges of unequal width, a stiffness factor must be included in equation” (a). ey Fig. 4, Frame Bending Stresses Flange Sending Stresses The flange bending stresses due to bolt-up and operating pressure for a long rectangular Flange (a/b = 2) can be approximated by considering a unit width of the flange at the center of the Tonger side. The pres- sure distribution in such a flange 1s. not uniform, but ‘the maximum is known €0 occur at this point. For this purpose it is convenient to introduce a factor (A which’ can be taken from the stress distribu: tion of a rectangular plate with fixed ends, listed in [6] and other texts on structural analysis. this. factor varies numerically from 0.308 for a/b= 1 to 0.500 for ay > 2, i Fig. 5, Flange Bending with Strip GasketFor flanges used with strip gaskets which are fully inside the Flange Bolts as. shown in Fig. 5, using the nomenclature of the ASME Code (1], Appendix 2, 35 muchas possible, the flange bending moment per unit Yength 1s given By Mae Hob tHeke + Hey Mss BbPh, + 2£mPho + (g-b) Phe 6) For flanges used with full face gaskets as per Fig. 6. the gasket compression on the outside of the flanges provides some resistance against rotation. This resistance has been included in the flange bending foment using the flange design method described in (8]- Using the nomenclature of Fig. 6 . He on Moe Ez (Hobe + Hee) Me 7 [BbPee + S(cbea)Ph] © be aye! e Fig. 6, Flange Sending with Full Face Gasket The moment in (6) and (6) must be resisted by a unit wath of the flange, assuming that the connecting Strip of shell plate ts_in direct tension only. This assumption 1s based on the fact that the shell plate attached to a rectangular flange is usually auch thin= ner and thus more Tiexible then the flange. The same Feasoning 1s made by the ASME Code, App.2 (1], in the case of the "loose optional flange", where the’ contri~ butions of the connecting shell’ in resisting bending are neglected. The section modulus of @ rectangular section of unit width ts 2S ey thus the stress in the flange cen be calculated by GMs 7B Stresses due to frame bending are combined with stresses due to flange bending for a safe design. At the inside of the flange, at the center of the long side, frame bending stresses are compressive and should thus’ be added to flange bending stresses occurring at ‘this location for flanges with strip gaskets. For flan- ges with full face gaskets, flange dending stresses Should be added to frame bending stresses at the inside and at the outside of the Flange. a0) It could be argued that flange and frame bending stresses occur in different planes and need not be combined; however, ina safe design method, it fs Suggested that these stresses be added to ensure a Flat and und'storted flange surface for easy sealing of the flanged Jotnt. For Flanges on non-reinforced rectangular pressure vessels, the connecting shel] plate is usually of con- Siderable thickness. in this case the frame bending Stresses on the flange are very small and need not be included ‘n the computations. EXPERIMENTAL WORK The experimental set-up fs shown in Figs 7. It consists of two pressure vessels: one unreinforced Vessel as shown in Fig. 8 and one rib-reinforced vessel Shown in Fige 9. Both vessels have the same flange dimensions and were tested bolted together. The flanges of both vessels were welded with full penetration welds to permit machining down the flange thicknesses in successive steps. To date four (4) cifferent flange thicknesses were tested, all with strip and full face gaskets, using two (2) different gasket -materials in two (2)' different thicknesses. The vessels were used in serfes of bolt-up and pressurization tests, some of the bolts were in- Strumented to ensure a correlation between bolt tor~ ques and Induced bolt stresses. © le > "ay T hae Fig. 7, Experimental Set-up 100=~ 34920276 2004 SAME | © | France © 3 Lit o| Bes | é at t | = | a (3875 ~ 4a lt aot gas a8 Fig. 9, Reinforced Test Pressure Vessel The two gasket materials used in the tests were the following: 3.2 mm thick conpressed mineral. fiber composition and 3.2 mm thick synthetic rubber with 75 Guroneter hardness. Both materfals are extensively used fn all process. industries. Strain gages were mounted along the center of the Jong side of both pressure vessels, biaxial strain gages. were used. The strain gage layout 1s shown in Fig. 7 TRANSVERSE STRESS (Pa) STRESS, (Pa) “ar Fig. 10, Stress Profite at 2070 kPa Pressure for Full Face Gasket FINITE ELENENT ANALYSIS To simulate the behavior of 2 rectangular flange under bolt-up and pressurization, a finite element analysis, using the ANSTS program was performed. Three Gtmensional isoparenetric ‘stress solid elements were Used. Due to symmetry, omy one quarter of the flange- Shell region a3 shown in Fig. 11 was included. C | | : [- of Fig. 11, Finite Cresent Grid 101To facilitate initial computations, a very simple mesh was chosen initially. This mesh was. then refined For more accuracy as shown in Fig. 12. Inttial results show that the solutions corresponding to the three grids converge. 7 4) ELEMENTS ELEMewrs Elements Fig. 12, Various Finite Element Grids NUMERICAL EXAMPLES Numerical examples are provided for the dimensions of the test. pressure vessels with strip and full face gaskets. A design pressure of 2070 kPa was assumed to Bermit comparison of calculated values with experimen- falcata, A'32 mm compressed mineral fiber gasket is used. Equivalent Circular Flange Method Dimensions are the same as for the unreinforced pressure vessel shown in Fig, 8, with equivalent circu- Var dimensions as given in Fig.'2. From C1], the gasket Constants are m= 2, y= Il MPa, € = 55 MPa, A, 36 ke Bs 3g lame > Ys Sad Hy» Epp © E(260°)(2.07)" 16770 N fas $(c-B)+ (344 - 268}= 38mm He aI 51880 .N 1d, fy b(c-3+0)* £(344-268+22)= 24.5 mm ZELt | (2f2o0o00V25%)3.2) | ~ Yregtt” ~(5.144)x (ssyers) 34 Mor 755(Hots + Hy &) = 3267700 Nimm Spe Wie (Essa 267 729) 109.3 pe HB (208(268) This compares well of 95 NPs shown in Fig. sure vessel. with a tangential stress value 10 for the unreinforced pres- For a strip gasket of 25 mm width, the method of the ASHE Code, Appendix 2 [1] 1s used. b= 12.5 mm, b= 2.5\b = 8.8mm G= 300.4 mm He Fate> E(300.49)2.07)* 146 680 N Hy + H-Hy* 146 630- 116770 = 29 860N Hes Hp 2b GmP = 69.060 N Wim * Ho Hp* (46 630+ 63060~ 215 690 N Wm, 215 699 , Sp 17 her tC 1254 mot $(344-309.4) = 218 mom hee Z (bys be)= 4 (38+ 21.8) = 2291 + My + Mg + My ~ Hobs t Habe + Hrbrs 6839 002 Nowa Spe Vite , (sutal{eas9 009) | » or tg (astyoeay 212 MPa The calculated stress of 210 MPa is 22% higher than the value of 172 MPa obtained from strain gage hneasurenents, hence the design method errs on the safe side. 102Frame Sending Flange Design Nethod For the reinforced pressure vessel. shown in Fig. 9, flange stresses for 2 full face gasket are calcu. ated using equations (5), (7) and (8). EB eis =y B45, ee ON /mm fw bhets D1 364?s 2648 Mente eb” 2 3eaez64 ” 874 969 Migs Me tay » CUBE 304 S60» 702 580 Co M , 702580, See Fs Homo 7 42 MPa Hy= BbP= (45{200)(2.07) = 186 N/mm Hy = £(c-b-d)P = $(54Y20.7) = 56 N/mm _ Eb be | (200 000/25%3.2) BE, 04 (ai{55Xo4*) « > 135 ee jy(Hokee Hy he) = 4842 N ron /mo s,- ou. (o¥aeae) bo rT ger = 46.5 MPa S* Sp4S, + 41.2+46.5 © 87.7 MPa This stress is higher than the measured value of 60.8 MPa at the outside of the reinforced pressure vessel, considering that the two calculated stresses do hot fully coincide with each other. As dlscussec above, however, the method thus yields a safe design. Using equations (5) and (6), flange stresses. are calculated for a strip gasket, sfnitar fo the ASHE Code sethod of Appendix 2 Ease He = 2émP (2¥ae)2i(2.07) = 73 N/mm 9+ c- 2b 276-(2Ys8)~ 232.4 mm -g) + $(276-232.4)= 21.8 mm \ z Hobs + Hebe + Hebe * L2030N mm /mm = (6102030). 96.3 ea 25" w + Se4 Sp 41.24 963+ 137.5 MPa ‘The measured stress for the strip gasket is only 90.5 ¥Pa, one third Tower than the value calculated. COMPARISON OF RESULTS Calculated values for rectangular pressure vessel Flanges of various thicknesses are compared with values from strain gage measurements for two types: (a) unreinforced pressure vessel, using the equi- valent circular flange wethed, Fig. 13 (b) rid-reinforced pressure vessel, using the frame bending flange design method, Fig. 14 It can be seen that the calculated values are always higher than the actual measured stresses, nence both design methods can be used for safe designs, within the Timitations discussed. we 30880 FLanae sTeees (Ma) Fig. 13, Stresses, Unreinforced Pressure Vessel FLANGE THICKNESS (mmm) 200 50 FLANGE STRESS (MPa) Fig. 14, Stresses, Reinforced pressure VesselcconcLusrons Comparing numerical values with experimental data, it appears that the method of equivalent round flanges is suitable for square and rectangular pressure vessel Flanges on unreinforced pressure vessels, within cer~ tain Timits. The results are on the safe side and become increasingly conservative as the ratio a/b in- The design method based on frame bending plus Flange bending. of a strip of unit width yields accept- able results for pressure vessel flanges of unreinfor- Ged. pressure vessels. This method 1s recommended for larger ratios of 2/3. All stresses calculated are on the safe side. For flanges on rib-retnforced rectangular pressure vessels, the method of frame bending plus flange ben- ding of a strip of unit width can be used to account for the stiffening action of the flange in planes perpendicular to the vessel axis. This method 1s ap- plicable to square or rectangular flanges. Calculated Stress values are considerably higher than measured stresses. Tt wi1l be interesting to see how calculated da and experimental values from strain gage measurenents Compare with results from a finite elenent analysis presently in progress. ACKNOKL EDGEMENTS The author wishes to acknowledge the financial support received from the following: Pressure Vessel Research Counct1, ‘Subcommittee on Bolted Flanged Connect ons Netural Science and Engineering Research Council of Canada The author also wishes to acknowledge the support of Bederca Ine., Montreal, for providing the test pres- Sure vessels and the gaskets. 104 REFERENCES a 1 ic) i) (1 7 te) (91 "ASME oiler and Pressure Yessel Code, Section VIII, Division 1, Pressure Vessels", The Anerican’Soctety of Mechanical Engineers, Now York, 1986 Edition. Blach, AcE. & Bazergut, At "Nethods ‘of Analysis of Bolted Flanged Connections - A Review", WRC Bulletin, 2M, Det 1981, pp 1-25. assidy, LK. & Kim, To. ‘Literature Search and Interpretive Study on ‘the Design of Bol ted Flanges. with External Loads. and Non-Circular Flanges", Unpublished Report, PVRC, Sep 1879, 57 pages. Blach, As: “Equivalent Circular Flange Method for Rectangular Pressure Vessel Flanges", Unpublished Lecture Notes, 1977, 6 pages. Blach, Au: "hectangular Pressure Vessel Flanges", Unpub! {shed Lecture Notes, 1978, 8 pages. Roark, Rud. & Young, WoCu: Formulas for Stress and Strain Fifth Edition, NeGraw-HiTl, New York, 1975 ‘Anonymous: "Design of Flanges for Full Face Gaskets", Taylor Forge Inc., Engineering Department Bulletin No. 45, Chicago, 1951. Blach, AE. = Bazergu, A. ~ Baldur, Rez "Bol ted Flange Connection with Full ‘Face Gaskets", WRC bulletin No. 314, May 1985, 15 pages; Blach, AE. "aol ted Flanged Connections for Non-Circular Pressure Vessels", Proceedings, Sixth International Conference on Pressure Vessel Technology, Beijing, China, Septenber 1968, pp 257-280.