Table of Contents
1.0 Disclaimer...............................................................................................................1
2.0 Nomenclature.........................................................................................................2
3.0 Codes and Standards...............................................................................................3
4.0 Results....................................................................................................................4
5.0 Design Of Bolt Holes In Joining Flange (work in progress)..................................5
6.0 Design of Joining Flange Connection to Clamping Shell....................................10
7.0 References............................................................................................................12
Appendix A – High Strength Bolts – Grade 8.8 (consultants, 2007)..............................13
Appendix B – Different Types Of Butt Weld (V.N.Vazirani,1985,p.g 71)....................14
Appendix C – Butt And Fillet Weld Size Illustration.....................................................15
Appendix D - Standard and Recommended Weld Preparation Details (AS1210-Figure 3.19.3(D).(c)(PP.170)......................................................................................................16
List of Figures
Figure 1: Joining flange connection to clamping shell......................................................4
Figure 2: A bolt subjected to full external load and full prying load................................5
Figure 3: General arrangement of joining flange and bolt holes.......................................6
Figure 4: Location of forces and bending moments at joining flange induced by internal pressure..............................................................................................................................6
Figure 5: Full penetration welded-on joining flange.......................................................10
Figure 6: Full penetration butt weld – Details.................................................................11
1.0 Disclaimer
This report has been written by an undergraduate student. Any information described
herein needs to be verified and approved by a professional engineer prior to be issued
for construction.
1
2.0 Nomenclature
A - outside diameter of joining flange (m)
A’b - total cross-sectional area of bolts required for operating conditions = W/Sb
Ab - cross-sectional area of bolt = π d2 (m2)
B - inside diameter of clamping flange (m)
C - bolt circle diameter (m)
d - bolt nominal diameter (m)
g0, g1 - thickness of clamping shell (m)
H - total hydrostatic end force (N)
HC - balancing reaction force outside the bolt circle in opposition to moments due
to loads inside the bolt circle (N)
hc - radial distance from bolt circle to outer edge of flange on which HC acts (m)
Le - effective length of the clamping shell (m)
MP - moment due to loads inside the bolt circle (Nm)
MC - moment due to HC
n - total number of bolts required for operating conditions
p - design pressure (Pa)
R - radial distance from bolt circle to point of intersection of clamping shell and
back of flange (m)
Sb - maximum permissible bolt design stress at design temperature (MPa)
W - minimum bolt load required for operating conditions (N)
2
3.0 Codes and Standards
This report should be read in conjunction with the following codes and standards:
AS 1210-2010 Pressure Vessels
AS 1554.1-2011 Part 1: Welding of Steel Structures
AS 3990-1993 Mechanical Equipment - Steelwork
Additionally, where there were no applicable Australian standards, the appropriate
British and American standards would be applied:
ASME BPV VIII-1 Rules for construction of pressure vessels - Flat Face
Flanges With Metal-To-Metal Contact Outside The Bolt
Circle
BSi-Enquire Case
5500/133 to PD
5500:2003
Specification For Unfired Fusion Welded Pressure Vessels -
Flat Unstayed Ends Of Non-Circular Shape And Associated
Flanges
3
4.0 Results
For rectangular metal-to-metal contact joining flanges, the total cross-section area of bolt holes required for operating condition would be determined by the following equation:
Ab' =
H +4 M c
( A−C )Sb
(1)
The number of bolts required would be:
n=Ab
'
Ab(2)
Details of joining flange connection to clamping shell have been illustrated as below:
Figure 1: Joining flange connection to clamping shell
4
5.0 Design Of Bolt Holes In Joining Flange (work in progress)
Since the leaking fluid would be sealed by injected sealant, there would be no gasket
required and, hence, the joining flange would be metal-to-metal contact. For flanges
with metal-to-metal contact outside the bolt circle, AS 1210-Clause 3.21.10 suggested
design method in Appendix Y, ASME BPV VIII-1, “Rules for construction of pressure
vessels”, as an equivalent method. It should be noted that the rules have applied to
circular flanged connections where the assemblage comprised of identical flange pairs,
and where the flanges were flat faced and were in uniform metal-to-metal contact across
their entire face during assembly before the bolts were tightened. This method assumed
the flanges were in tangential contact at their outside diameter. The analytical procedure
was based on the prying effect. Illustration of this effect has been shown in Figure 2:
Figure 2: A bolt subjected to full external load and full prying load
From Figure 2, due to the flange interaction beyond the bolt circle to resist the bending
moment developed by the external load, H , a bolt was not only subjected to the full
external load, H , but also the prying load, H R, or the joint would fail. Hence, the bolt
load would satisfy the following condition:
5
FB ≥ H +H R (3)
It was important to note that the operating bolt stress was relatively insensitive to
changes in prestress up to a certain point and that thereafter the two stresses were
essentially the same. In other words, the assembly stress in the bolts would have no
significant effect on the actual operating stress in the bolts.
General arrangement of the assemblage has been shown in Figure 3:
Figure 3: General arrangement of joining flange and bolt holes
Location of forces and bending moments have been illustrated in Figure 4 below:
Figure 4: Location of forces and bending moments at joining flange induced by internal
pressure
6
According to ASME BPV VIII-1-Appendix Y-9, the total cross-secional area of bolts
required for operating conditions has been defined by the following equation:
Ab' =
H +2 M P
( A−C )Sb
(4)
The Equation 4 provided for circular flange. For rectangular flange, using Figure 4 and
Equation 3 for minimum bolt load required at operating conditions:
W =FB=H2
+H c (5)
in which H has been defined by Equation 15 (Semester 1-progress report),i.e.,
H=PB Le . Also,
H c=2 M c
A−C (6)
Substituing Equation (6) into Equation (5):
W =H2
+2 M c
A−C=1
2A
b
'
Sb (7)
The expression Ab' Sb multiplying by
12
indicated the bolt load in each joining flange.
Rearranging Equation (7) would yield the total cross-secional area of bolts required for
operating conditions for rectangular flanges:
Ab' =
H +4 M c
( A−C )Sb
(8)
7
Due to symmetry, the balancing moment M c developed by H c would be equal to half
the moment M P developed by H which could be expressed as
M c=H2
×C2=
M p
2 (9)
From Figure 3,
C=B+2 (g+R ) (10)
In which g could be obtained from Equation 2, semester 1- progress report; R should be
sufficient to provide clearance for washer seating,i.e., dimension ‘D’ Appendix A, and
welding at flange connection to clamping shell defined in Clause 6:
R ≥D2
+G (11)
Dimension ‘G’ could be seen in Appendix D as a reference.
From Figure 3,
A=C+2 hc (12)
The minimum and maximum distance from bolt centre to edge of flange have be
designed in accordance with AS3990–Clause 9.6:
hcmin=1.5d (13)
hcmax=12 g but not exceed 150 mm (14)
8
For bolt grade 8.8 described in Appendix A, the minimum tensile strength, Fuf ,would be
800 MPa and the minimum yield strength, FYf ,would be 640 MPa. According to
AS3990–Table 9.5.2 (PP.58), the maximum permissible stress, F tf , subjected to tension
would be the smaller of:
0.60 FYf=0.60 ×640=384 MPa (15)
0.45 Fuf=0.45 ×800=360 MPa (16)
Hence, the maximum permissible stress of the bolt, F tf=Sb, would be 360 MPa.
The number of bolts required would satisfy the following condition:
n ≥Ab
'
Ab(17)
Refering to Figure 3 and Equation 6, the prying force could be reduced, and hence the
bolt load, by increasing the distance hc, minimising the distance R. It has also been
shown that by increasing the joining flange thickness to make it more rigid, the prying
effect would be reduced or eliminated. Under these conditions the bolt would just react
to an external just the way it would if the external load were applied axially
(Bickford,1990).
9
6.0 Design of Joining Flange Connection to Clamping Shell
The welded joint between the flange and the clamping shell has been designed in
accordance with AS1210, AS1554.1, and AS3990. There have been many types of
flange attachement specified by AS1210-Figure 3.21.3(PP.189). It has been suggested
by Dave Landwehr that full penetration butt weld would be employed for the design.
The advantages of this type were that there would be no limit in maximum calculation
pressure and temperatures (AS 1210, Clause 3.21.3.3),i.e., it could be still applicable
when the design pressure and temperature were needed to be improved, and no
calculations were neccessary as the maximum permissible stresses would be the
minimum value pertaining the components jointed (AS 3990-Clause 9.8.2). However,
for butt welds, the members to be connected had to fit perfectly when they were lined
up for welding and edge preparation was also required,i.e., chamfering. Normally, a
backup plate was also temporarily required to ensure full penetration and a sound weld.
Hence, this attachment method would require more skilled supervision and be costlier.
Various type of the butt welds could be seen in Appendix B as a reference. The typical
arrangement of full penetration welded joining flanges has been shown in Figure 5:
Figure 5: Full penetration welded-on joining flange
(AS 1210, pg.189, Figure 3.21.3 (c))
In which t n (or go) was the nominal clamping shell thickness. In such connection, the
joining flange was considered to be the equivalent of an integral structure and the clamp
shell was considered to act as a hub. However, this design provided for circular flanges.
Design for rectangular flanges could be refered to AS/NZS1554-Clause 3.2 in which the
joining flanges were attached to the clamping shell to form a T-joint. As specified by
this clause, weld size would be the thickness of the joining flanges, which was also
10
known as throat thickness. The effective length of the weld could be taken as the length
of the joining flange in which a continous full-size weld was achieved. The effective
area would be the product of the effective length and the design throat thickness. For
this type of joint, a small fillet weld of 6 mm size was also superimposed on each
welded face. Definitions of size of butt and fillet weld could be refered to Appendix C.
Weld preparations have been designed in accordance with AS1210-Figure 3.19.3.(D).
(c)(PP.170) which could be seen in Appendix D. Details of the full penetration butt
weld have been shown in Figure 6:
Figure 6: Full penetration butt weld – Details
11
7.0 References
Committee ME-001, Pressure Equipment. 2010. As 1210. Standard Australia Limited
Committee ME-001, Pressure Equipment. 2008. As 1548-Fine Grained, Weldable Steel
Plates for Pressure Equipment. Standards Australia
Committee ME/5, Cranes. 1993. As 3990-Mechanical Equipment-Steelwork. Standards
Asutralia (Standards Association of Australia)
Consultants, PDC. 2007. High Strength Bolts – Grade 8.8.
Engineers, The American Society of Mechanical. 2004. Rules for Construction of Pressure Vessels.
Bickford, John H. 1990. An Introduction To The Design And Behaviour Of Bolted Joints. USA: Marcel Dekker.
V.N.Vazirani, M.M.Ratwani. 1985. Steel Structures and Timber Structures: Analysis, Design and Details of Structures. Vol. 3. Delhi: Khanna.
Bickford, John H. 1990. An Introduction To The Design And Behaviour Of Bolted Joints. USA: Marcel Dekker.
V.N.Vazirani, M.M.Ratwani. 1985. Steel Structures and Timber Structures: Analysis, Design and Details of Structures. Vol. 3. Delhi: Khanna.
V.N.Vazirani, M.M.Ratwani. 1985. Steel Structures and Timber Structures: Analysis,
Design and Details of Structures. Vol. 3. Delhi: Khanna.
V.N.Vazirani, M.M.Ratwani. 1985. Steel Structures and Timber Structures: Analysis,
Design and Details of Structures. Vol. 3. Delhi: Khanna.
12
Appendix A – High Strength Bolts – Grade 8.8 (consultants, 2007)
Size A B C D E FX
(Min.)
Min.
Length
M12 18 20 8 28 4.6 32 24 25
M16 27 31 11 34 4.6 32 28 40
M20 32 37 14 39 4.6 38 32 40
M24 41 47 16 50 4.6 44 36 50
M30 50 58 20 60 4.6 57 42 75
M36 60 69 24 72 4.6 57 48 90
Note: All dimensions in millimetres.
13
Appendix B – Different Types Of Butt Weld (V.N.Vazirani,1985,p.g 71)
14
Appendix C – Butt And Fillet Weld Size Illustration
15
Appendix D - Standard and Recommended Weld Preparation Details (AS1210-
Figure 3.19.3(D).(c)(PP.170)
LEGENDS
α = 50o min.
S2 = 0 to 3 (mm)
g2 = 3 (mm) min.
Dimensions E, F and G have been designed based on the reccomended α of 50o, S2 of 3
mm, and g2 of 3 mm and defined by the following expressions:
E=t f −3
2
F=E × tan (500 ) (18)
G=E+F (19)
16
Tabulation of E and F corresponding with various commercial plate thicknesses has
been shown in table below:
Flange thickness, t f
(mm)E (mm) F (mm) G (mm)
14 6 7 13
16 7 8 15
18 8 9 17
20 9 11 20
22 10 12 22
25 11 14 25
28 13 15 28
30 14 17 31
32 15 18 33
36 17 20 37
40 19 22 41
45 21 25 46
50 24 28 52
55 26 31 57
17