Reference:

1. Pressure vessel design manual by Dennis R. Moss and michael basic fourth edition 2013.
2. modern flange design by taylor forge engneered enc, michel G kilkenny february 23,2010.
3. ASME 2007 asme boiler & pressure vessel code 2007 edition ,july 1, 2007.
4. Indian Standard (IS: 4864-4870): Shell Flanges for Vessels and Equipment, BIS 1969,
New Delhi.
5. Kuppan T. Heat Exchanger Design Handbook, Marcel Dekker, Inc. 2000, New York.
6. ASME B16.5-, Pipe Flanges and Flanged Fittings edition, July 9, 2003, Three Park Avenue,
New York, NY 10016-5990.

AASME B16.5-2003SME B16.5-2003

 Renu Rani1,Abhishek Kumar2,Lalit Patoda 3,
Aceelerator And Pulse Power Division , Bhabha Atomic Research Centre (BARC),Vizag,
Civil engineering division Bhabha Atomic Research Centre (BARC),Vizag
Engineering Service Division, Bhabha Atomic Research Centre (BARC),Vizag,

Analysis and Design of Gasket seal flange Assembly for Leak Tightness
Abstract:
A model of bolt flange and gasket assembly are created using the ASME /ANSI and IS standard.
ASME codes are based on basic equation generated by equilibrium calculation.
FEA Analysis of flange assembly to examine the gasket stresses variation along the
circumference by applying different diameter bolt and by varying the number of bolt. The
objective of this report is to validate the seating stresses on the gasket pressurized and non
pressurized condition by applying the bolt load .Seating stress necessary to seat the gasket or
joint contact surface properly for its effective function. This is the minimum stresses required to
compress the voids of the gasket and to fill the surface irregularities, that minimum stress not
necessary to be on the complete gasket but should be at least on effective gasket width.
Introduction: APPD(Accelerated Pulse Power Division) dealing with SF6 and N2 gas
pressurized chamber and vacuum chamber in most of the systems to increase the break down
voltage and reduce the gap between spark gap. To make the leak proof chamber types of seals
are used. Non standardize flanges are uses as per system requirement to ensure the leak proof of
these flanges ,bolt and gasket dimension are calculated by ASME section VIII div I and
analyzed the gasket by FEA analysis.
Analytical calculation for flange design:

Cylinder diameter and thickness:

Cylinder having nominal diameter D. The shell thickness can be calculated from the equation
below based on the maximum allowable stress and corrected for joint efficiency.[5]
𝑃𝐷𝑠
𝑡𝑠 = +𝐶 (1)
𝑓𝐽−.6𝑃

ts = Shell thickness
P = Design pressure
Ds = Shell ID
F = Maximum allowable stress of the material of construction
J = Joint efficiency (usually varies from 0.7 to 0.9 depends on type of weld)
C = Corrosion allowance
 Thickness of gasket , IS: 4864-4870

Thickness (mm) Gasket width, N (mm)

3 Up to 20

4 Over 20 and up to 30

5 Over 30

Gaskets design[3]:
A gasket used to create and retain the static seal between two stationary flanges. these static seals
aim to provide complete physical barrier against the fluid contain within, and so block any
potential leakage path.

“m”= maintenance factor

A factor that provides the additional preload needed in the flange fasteners to maintain the
compressive load on a gasket after internal pressure is applied to a joint. The net operating stress
on a pressurized gasket should be at least (m) x (design pressure,)

“y” = Minimum design seating stress

“y” factor is the minimum design stress on the contact area of gasket necessary to provide a seal .
The “y” value can be thought of a minimum stresses required to compress the voids of the gasket
and conform gasket to the flange surface
DOG =outside gasket diameter;
DIG = Inside gasket diameter;
P = Design pressure;

Gasket width calculation;

DOG −DIG
Gasket width, N=
2
DOG +DIG
Gasket mean dia , G=
2
DIG = Gasket inner diameter
DOG =Gasket outer diameter
Basic gasket seating width, bo = N/2
Effective gasket seating width, b = bo, if bo<=0.25 inch
= 0.5 √bo , > 0.25 inch

BOLT DESIGN:
The bolt design procedure is as follows:
The minimum initial bolt load at atmospheric pressure and temperature is given by
Wm1= 𝜋𝑏𝐺𝑦 (4)

The gasket is compressed under tight pressure. The required bolt load is given by:
𝜋
Wm2 = Hp +H = 2𝜋𝑏𝐺𝑚𝑝 + 𝐺 2𝑃 (5)
4

Where mean gasket diameter

𝐷𝑂𝐺 +𝐷𝐼𝐺
G= (6)
2

Total hydrostatic end force

𝜋
H = 4 𝐺 2𝑝 (i)

Total joint contact surface compression load

HP =2𝜋𝑏𝐺𝑚𝑝 (ii)
Controlling load for bolt design is greater value of wm1 and wm2
Than required bolt cross section area Am based on controlling load wm1 and wm2

𝑤𝑚1 𝑤𝑚2
𝐴𝑚1 = or 𝐴𝑚2 = (7)
𝑓𝑎 𝑓𝑏

Required bolt area is the maximum value of 𝐴𝑚1 and 𝐴𝑚2 .

𝑓𝑎 = Allowable bolt stress at ambient

𝑓𝑏 = Allowable bolt stress at design temperature
(Selecting the bolt diameter and flange dimension (E, R value) from Taylor Forge Engineering
Product, Bolting Data TABLE 1 pg. no. 28 )

 For selected bolt from table the actual bolt area can be calculated as Ab , Ab Always
should be greater than Am
 (Bolt diameter should not be less than ½” to avoid over stressing)
𝐴𝑏 𝑓𝑏
 Minimum gasket width, 𝑁𝑚𝑖𝑛 =
2𝜋𝑦𝐺
N should be greater than 𝑁𝑚𝑖𝑛
(𝑨 𝒎 +𝑨𝒃) 𝒇𝒂
 The flange bolt load, 𝑊= For gasket seating condition
𝟐

(8)
𝑊 = 𝑊𝑚2 For the operating condition

Spacing of bolt:
Maximum spacing of the bolt can be specified as 2a+ 6t / (m+.5) and minimum bolt spacing
controlled by the requirement of nut and wrench clearance as (2a+t) from Taylor Forge
Engineering Product
a = bolt diameter
t = thickness of flange
m = gasket factor
Flange Design:

Weld Neck Flange (Raised Face):

Flanges are piping components used for connecting pipes

Fig-1: Weld Edge Flange

RF (Raised Face) value for class 150 and for class 300 is 0.06” and for class 400 and above is
0.25” (ASME pipe and flange B- 16.5, 2003)
Minimum value of g1 is 2go and slope of the tapered hub is not less than 1:3 (Taylor Forge
Engineering System)
E, R Value from Taylor Forge Engineering Product, Bolting Data TABLE 1 pg. no. 28 )
PCD (pitch circle diameter) calculated as, ( B+ 2g1+ 2R) (9)
OD of the flange, (B+2g1+2R+2E) (10)

Calculation of flange forces:

Fig-2: Forces Acted On Flange

Hydrostatic end force on area inside of the flange is given by
𝜋𝐵2 𝑝
𝐻𝐷 = (11)
4

Pressure force on the flange face, HT = H-HD (12)

Gasket load under operating conditions HG = W-H (13)
Calculation of flange moment:
1) Calculate the summation of flange moments for the operating condition;
Mf = MD + M T + M G (14)

Moment due to HD , MD = HD hD
Moment due to HT, MT = HT hT
Moment due to HG, MG = H G h G

(Where: Moment arm for flange load under operating condition)

hD = R+0.5g1
𝐶−𝐺
ℎ𝐺 = C = bolt circle diameter
2
𝑅+𝑔1 +ℎ𝐺
ℎ𝑇 = G = nominal gasket diameter
2

2) The flange moment for the gasket seating condition:

𝑊(𝐶𝑏 −𝐺)
Mfo = 2

Stresses on flange:

Longitudinal hub stresses:

fMo
SH = Lg 2B (12)
1

Radial Flange Stresses:

(1.33te+1)Mo
SR = (13)
Lt2 B

Tangential flange stress

𝑌𝑀𝑂
𝑆𝑇 = − 𝑍𝑆𝑅 (14)
𝑡2𝐵

Where:
𝑡𝑒 + 1 𝑡 3
𝐿= +
𝑇 𝑑
𝑈
d= 𝑉
ℎ𝑜 𝑔𝑜2

t = thickness of flange,
T,Y,U and Z are value corresponds to K (K=A/B) from chart FIG. 2-7-1,
e = F/ho, (ho=√Bgo) and F is value from chart corresponding to g1/go and h/ho FIG. 2-7-2,
V is value from chart corresponding to g1/go and h/ho FIG. 2-7-3,
ASME 2007 boiler and pressure vessel code appendix 2 ( FIG 2-7-1, FIG 2-7-2, FIG2-7-3)

Flange Thickness:
Flange thickness for weld edge flange can be calculated by solving the equation (13) and (14),
value of SR and ST are the allowable stresses for the flange. Check the value of longitudinal hub
stresses should be less than that of allowable stresses of the flange.
OR
t(trial) =0.72√(MoY/ BSa) from Taylor Forge Engineering
by putting this t (trial) in all three above equation stresses should be below permissible stress.

EXAMPLE:

Shell design:
Designing a weld neck flange of CARBON STEEL for the pipe having ID 12 inch or 304.8 mm
. For internal pressure 2 Mpa at atmospheric temperature.
Thickness of pipe from eq(1) is calculated as 9.28~ 9.5 mm
From ASME Standard:
For carbon steel 1/16-inch minimum corrosion allowance.
For stainless steels, a 1/32-inch minimum corrosion allowance.
f = allowable stress for carbon steel 100.6 Mpa.
J = joint efficiency taken as .8
OD of shell = ID + 2(tS) = 323.8 mm

Gasket dimension calculation:

Gasket Dimension For P=2 MPa and B=12” selected from, ASME B -16.20
DIG = 342.90 mm
DOG = 406.40 mm
For aluminum gasket m and y value from ASME table 2.5.1
m=4
y = 61 MPa
 Gasket parameter

G (mm) N (mm) tG (mm) bo (mm) b (mm)

374.65 31.75 4 15.88 2.00

From above equation (2) and (3)

Bolt dimension calculation:

Bolt area calculated as

max (wm1,wm2)
fa (Mpa) Am(mm2)
(N)

258014 100 .6 2564

Bolt from table selected as having diameter ¾”,7/8” ,1” inch from bolting data-table and no of
bolt are 12 , 8, 8 from calculation

Flange dimension:
Case –I
For bolt diameter ¾” flange dimension are calculated as, PCD 422 mm, OD 464.8 mm and
minimum thickness 25 mm .
Case-II
For bolt diameter 7/8” flange dimension are calculated as, PCD 428 mm, OD 476.8 mm and
minimum thickness 25.5 mm .
Case -III
For bolt diameter 1” flange dimension are calculated as, PCD 434 mm, OD 488.8 mm and
minimum thickness 26 mm.
FEA analysis:
Model of two flange, bolts (carbon steel), and gasket has analyzed. Gasket is made-up of flat
aluminum 6061 alloy havig yield stress 55.15 and ultimate stress Stress are applied on the bolt is
120 MPa is allowable stress of carbon steel (0.6*yield stress). Considering the non linear
behavior of aluminum, Aluminum gasket plastically deformed to fill the irregularities and voids
between the faces.
 Fig-3: Flange Bolt And Gasket Assembly

Assembly analyzed by finite element method, meshing to these components by fine meshing
with C3D8R element. For all three cases of type of bolts and no of bolts stress varies along the
periphery of gasket as well as radial direction
For case -III
When bolt size is 1” no of bolts are 12 stresses variation along the periphery of gasket as shown
in the Fig 4 in quarter part of gasket . As we can see figure the stress variation are high where
end of raised face interact with gasket .stresses are high at bolt location and lower in middle of
two bolts.
 Fig 4:
Stresses variation along the gasket for 12 no of 1” bolt

stress plot circumferentially along the gasket where end of raised face and gasket interacts. this
shows compressive stress developed on gasket in the range of 70 MPa to 77 Mpa
 Fig 5: circumferentially stress variation along gasket
stress varies radialy along the gasket as it not equally compressed every point .vatiation of stress
along the gasket radially near the fastener is shown in the fig 6.stresses near the fastener are high.
As figure shows 6 mm width of gasket is subjected to stress more than 61 MPa this width is
more than that of effective gasket width.

fig:6 stresses variation radialy along gasket near fastener

fig: 7: stress variation along the gasket width in middle of two fasteners
In middle of two fasteners stresses are lowest as figure shows that width of the gasket that
subjected to stresses more than 61 Mpa is 4 mm .This is more than that of gasket effective
width.hence this fklange bolt and gasket assembly is leak tight.