Equipment Design: Mechanical Aspects

Prof. Shabina Khanam

Department of Chemical Engineering
Indian Institute of Technology - Roorkee

Lecture 15
Design of Flanges

Welcome to the fifth lecture of week 3 where we will discuss design of flanges. If you remember
lecture 2, 3 and 4, there we have discussed details of flanges and design procedure. In this
particular lecture we will discuss, we will solve a few examples related to design of flanges. So
let us focus on example 1.
(Refer Slide Time: 00:48)

In this example, we need to design a loose-type flange with plain face. So loose-type flange that
you must have understood that it is basically lying over the pipe and second point we have is the
plain face. So that face we have discussed in lecture 3. And this flange is to be designed for
reactor shell with 1.8 meter outside diameter. So D o is given as 1.8 and 0.018 thickness g o.
Now what is g o, if you remember g o is basically width of upper section of welded-neck, okay.
So if g o is given we should understand that it is the width of lower section of welded-neck.

Other specifications are design temperature is 200, design pressure 2.2 meganewton per meter
square. Allowable stresses for flange material and bolting-up material are equal and which is
120 meganewton per meter square. Gasket material is given as corrugated soft aluminum metal
asbestos filled where minimum design seating stress is 20 meganewton per meter square. Gasket
factor is given as 2.5 and minimum actual gasket width is 10 mm.

Ratio of gasket internal diameter to shell outside diameter is 1.01, corrosion allowance is 0, weld
joint deficiency factor is 1. What we need to find is effective gasket seating width, minimum
bolting area and which amongst the following bolts will be used for bolting the flange. Here we
are given four bolts M 36 x 3, 39 x 3, 42 x 3 and 45 x 3. And g 1 is given as 1.415 g o.
(Refer Slide Time: 02:32)

So basically once I know g 1 it means the flange is welded-neck, only if g o value is given it may
be welded-neck or it may be tapered neck, but g 1 will decide whether it is welded-neck or not.
Next I need to compute is bolt circle diameter, then flange outside diameter after adding 2 cm
assumed gap between end of bolt circle and end of flange. Estimate various loads and moments
under operating as well as bolting-up condition and then calculate the flange thickness for
Poisson’s ratio given as 0.3.
(Refer Slide Time: 03:42)
So in this example we are coving almost all parts related to design of flanges. So let us start to
solve these parts one by one. First of all we have to find out effective gasket seating width and
for this purpose I have to calculate the gasket dimension that is the width of the gasket. And for
that purpose I will start with the given ratio d i/D o is 1.01, d i is the inner diameter of gasket. So
d i would be 1.01 x 1.8, so 1.818 meter we can find as d i.

Further I am having d i/d o and here this d o is small d o not the D because this d o is the outer
diameter of gasket, okay. So d i/d o both are related to the gasket and here y is given as 20 and
m is given as 2.5, other value we can put and then we can calculate d o, so outer diameter of
gasket is coming out as 1.974 meter, inner diameter is equal to 1.818. So considering these two
values we will calculate minimum gasket width and which comes out as 78 mm.

Now if you remember the problem, there we are given minimum actual gasket width should be
10 mm and here I am getting 78 mm. So whatever would be higher that I need to take, but here
the comparison of this value with the actual minimum gasket width given in the standard or
given in the table that is required. Here I am having minimum gasket width which comes out as
78.

And if you remember the problem there we have seen that minimum actual gasket seating width
is 10 mm. So higher value of calculated and given value I have to take as value of N, but here I
need to compare the given value with the calculated value. So N final would be 78 mm and
therefore b o value we can find as N/2 which is equal to 39 mm. This b o is basic gasket seating
width, which is used to calculate effective gasket seating width.

And here I am having two conditions. In this case this condition will be applicable because b o
is greater than 6.3 and therefore b we can find as 15.61 mm. So in this way we can calculate
effective gasket seating width. Now this seating width we will use to calculate value of g, where
g is the diameter of reaction of load in the gasket.
(Refer Slide Time: 06:40)

Next part of the problem is to calculate minimum bolting area and whatever effective gasket
width will be computed that we will used to calculate value of G and as this condition will be
applicable G would be computed as g o – 2 b. So 1.974 – 2 x 15.61/1000 because that is given in
mm. So G comes out as 1.94278. So once I know the G value I have to find out load at
operating condition and bolting-up condition and then we will find out respective area and then
we can calculate the bolting area.

So using value of G as well as design pressure I can calculate H by this expression which comes
out as 6.522 meganewton. H p we can calculate by this expression Pi g x 2b x m P and that
comes out as 1.048 meganewton. Total load in this case would be 7.57 meganewton. And then
we have to focus on bolting-up condition where W g I need to find by this expression, where W g
is equal to Pi (G x b) x y. Putting all these values over here we can have W g as 1.0955
meganewton.
So here we have to find out S g or S o, and So is basically allowable stress of bolt material at
design temperature and considering that we can find out bolting area at operating condition and
which is equal to W g x S o and which is equal to 0.06308 m 2. And further we have A bc which
is equal to W g/S g which is equal to 1.9055/120 and that is equal to 0.01588, okay. Now what is
the point you have to focus on is this point.

In this particular case I am taking S g and S o constant, which is equal to 120 meganewton per
meter square, now why it is so because if you remember the design procedure there we have
discussed that S o is the allowable stress of bolt material at operating condition or at design
temperature, okay. And S g is the allowable stress of bolt material at atmospheric temperature.
And here in this problem, allowable stress of bolt material is given as 120, okay.

So now why these two values I am taking equal because if you remember what is the design
temperature, design temperature is 200, and if you remember allowable stress table, okay which
we have discussed in terminologies and many previous lectures, there minimum value of
allowable stress is available at 250 degrees Celsius and design temperature is less than 250.
Therefore I have to take S o at 250 degrees Celsius.

And if I am considering atmospheric condition, atmospheric condition we can have 25 degrees or

so, but because allowable stress value is not available for temperature less than 250 for
atmospheric condition also I have to take value at 250. Therefore in this particular case both
allowable stress values at operating condition as well as at bolting-up condition are equal
because temperature is 250 in both case. I hope you are getting this.

For example, if design temperature is given as 300 or 350, so you have to take S o at 350 and S g
at 250. I hope I am clear. So here I have computed A o as well as A bc and minimum bolting
area will be considered maximum of this two and which is equal to 0.063. So that area we will
use to calculate the optimum bolt and bolt circle diameter, okay. So let us start calculation of
that.
(Refer Slide Time: 10:46)
If you remember the problem it is given as we have four different bolts and I have to choose the
optimum bolts among these, okay. So for that I know g 1 value, I know g o, so I can calculate g
1 as 0.02547. First bolt I am having is M 36 x 3, where root area I have to calculate as equal to
Pi/4 (36-6) whole square and which comes out as 706.858 mm 2.

Now minimum number of bolts would be minimum bolting area divided by root area, so it
comes out as 89.127 and then you have to take actual number of bolts, which should be multiple
of 4 to this and then that value comes out as 92. Once I am having the actual number of bolts I
will calculate C 1 and C 2. So C 1 would be equal to n B S/Pi which is equal to 92 x 80/Pi. Now
from where that 80 comes, it is available in this table. I am having bolt 36 x 3, so B s value is
given as 80, so that I have kept over here.
(Refer Slide Time: 12:15)
So C 1 comes out as 2.343. Further C 2 I have to calculate and which is equal to ID+ 2 (g 1 +
R). So ID is basically inner diameter of flange and which is equal to outer diameter of Pi, so C 2
would be equal to 1.8 + 2 g 1, which we have already calculated, R we have taken as 0.05, which
is given in this table corresponding to 36 x 3 bolt. So considering these values we can have C 2
as 1.951 meter and then I have to find out difference between C 1 and C 2 and it comes out as
0.392 meter.
(Refer Slide Time: 13:10)

In the similar line I will calculate for other bolts also. Like for M36 x 3 we can calculate root
area as this, minimum number of bolt I can calculate as 73.658 and next multiple 4 is available as
76, so that we have taken as actual number of bolts. C 1 is n B S/Pi, so if you consider this 39 x
3 bolt, it has 86 as B s and 52 as R.

So B s as 86 we can consider in C 1, which comes out as 2.0805 and C 2 will be equal to 1.8 + 2
and this g 1 and this corresponding R which is 52 mm, okay. Now if you see this table, all values
are given in mm, even these values, okay. All these values are given in mm. So C 1 – C 2 in this
case is 0.1256.
(Refer Slide Time: 14:20)

For next bolt, which is 42 x 3, we can find out root area which comes out as 1017.876 mm 2,
minimum number of bolts 61.89, actual bolts would be 64. C 1 we can find as 64 x 91/Pi. So
this is corresponding to 42 x 3, 91 would be the B s that we can use over here. And then C 1
comes out as 1.854 meter. Further I am having C 2, where I will use value of R and which is
equal to 55 mm that we will use over here. And then we can find C 2 as 1.961 meter. So C 1 – C
2 will be equal to -0.107 meter.
(Refer Slide Time: 15:12)
In the similar line I can calculate for bolt 45 x 3, where actual number of bolts are 56 and in this
case, it is 45 x 3 B s 96 and R is 57. So these values I can use over here to calculate C 1 and C 2
respectively. And then C 1 can be found as 1.711 meter and C 2 as 1.965 mm, difference of these
two would be -0.254. So in this way we have calculated all parameters related to four bolts.
(Refer Slide Time: 15:52)

Now we will summarize the results of these bolts. So summary is given in this table, where I am
having the bolt C 1, C 2 and C1 – C2, okay. So you can see here that I have to choose the bolt
which has C 1 – C 2 positive and least. So it will come out for this particular bolt and
accordingly the bolt which I have to choose is 39 x 3, so 39 x 3 will be used for bolting the
flange, okay.
(Refer Slide Time: 16:21)

So once I have chosen the bolt, I can see the value of bolt circle diameter and if you consider this
table bolt circle diameter would be C 2 of the respective bolt, okay. So now bolt circle diameter
would be C 2 of that bolt, which comes out as 1.9549 meter and then we have to find out flange
outside diameter, okay.

Flange outside diameter how I can calculate because C is there so that C + 2 x bolt radius + 0.04,
so C is coming as 1.9549 x bolt diameter or you can use 2 x bolt radius, it is same. And then
0.04, why this is 0.04 because it is given that gap between the outer diameter of bolt circle to the
outer edge of the flange is given as 20 mm. So in that case we are considering 40 mm because
both sides I have to consider to calculate the diameter. So therefore 40 mm is added over. So
total flange outside diameter comes as 2.0339 meter.
(Refer Slide Time: 17:44)
And next I have to estimate the load and moment under operating as well as bolting-up condition
because now I have to calculate the thickness of flange. Let us focus on operating condition and
then we will move to bolting-up condition. For operating condition we have three load W 1, W
2, W 3 and you can find that W 1 as Pi B 2/4 x p which comes out as this. W 2 you can have as
0.924 and W 3 is 1.048. So considering all these loads we can have total load of 7.57
meganewton.

So this load you can also observe while computing the bolting area, okay. Now once I am
having this bolt, I have to calculate the arms to find out the moment. So these arms are given as
a 1, a 2 and a 3. So a 1 is equal to C – B/2, so here I can put the value C – B/2, which comes out
as 0.07745 meter, a 3 I can consider as 0.00606 meter, which is nothing C – G.
(Refer Slide Time: 19:02)
And in the similar line I can calculate a 2 as a 1 and a 3. Here this is not a 2, this a 3/2 which is
equal to 0.041755 meter and then considering all these arms as well as load I can calculate the
moment at operating condition and which comes out as 0.4785 meganewton meter. Further I
have to focus on bolting-up condition, where M g is equal to W x a 3, and W we can define as A
m + A b/2 x S g. So S g is basically the allowable stress of bolt material and A b is given as
number of actual bolt into root area, which comes out as 0.065.

So root area you will choose corresponding to 39 x 3 bolt, okay. So considering all these values
we can have W as 7.68 meganewton and then you can find out M g as 0.054654 meganewton
meter. Further I have to calculate M as maximum of M o as well as M g and which can be taken
as 0.4785 meganewton meter which is corresponding to M o value.
(Refer Slide Time: 20:38)
Now once I am having the flange moment I will calculate the thickness of flange, where
Poisson’s ratio is given as 0.3, okay. So here this is the expression to calculate the thickness
where M we have already computed in last slide. C f I have to take as 1 as a initial guess, B is
basically bow diameter or inner diameter of flange or outer diameter of shell. S fo is the
allowable stress of shell material and Y is the factor which we can compute through this.

So to find out Y value I have to consider k as A/B, which comes out as 1.13 and then putting k
value as well as Mue in this expression I can find Y as 15.9066 and then we can calculate
thickness of thickness, that is t 2 = 0.4785 that is M x C f, which I have taken as 1 as initial guess
divided by B x S fo x Y, so t comes out as 0.1877 meter. Considering this t we will find out
revised value of C f which is given as B s/2d + t.

So B s we have to consider as revised value, which can be computed by this expression, where C
is the bolt circle diameter which we have chosen. So B s is equal to Pi x 1.9546/n where n is the
actual number of bolts corresponding to 39 x 3 bolt. And therefore B s is 80.509 mm. So that B
s I have kept over here. Then this is nothing but 2 d because 39 is there, so 78 mm I can consider
as 2 d.

And this thickness I have considered over here to calculate C f and corresponding value of C f is
0.5513, okay. Once I have calculated C f 0.5513 I will use this C f in this expression in place of
1. Then t I can find out and then further considering this t value at this place I can find revised
value of C f, which comes out as 0.6095. Considering this C f I will calculate t, which is 0.1466
and then C f and then t and then C f and then t, like this we keep on moving till two consecutive
values of t would be equal almost.

So here we have final value of thickness is 0.1455, which is almost equal to the previous value of
t and therefore this we can consider as final thickness of flange. So in this way we have
computed all parts for flange design and I hope the method is clear to you. Now we will
consider another example for design of flange.
(Refer Slide Time: 23:56)

Now here we have example 2, in which we are designing again a loose-type flange, which is
used to join two parts of shell with OD as 0.8 meter. Design this flange for following
specification that is plain face, design pressure is given like this and design temperature here as
400. Allowable stress of shell material 120 meganewton per meter square. Allowable stress of
flange material at design temperature is given as 130 meganewton per meter square.

And bolts are made with IS:2002-1962 2A material. Gasket material is soft aluminium solid flat
metal. Ratio of gasket internal diameter to shell outside diameter is 1.02, corrosion allowance 0
and joint deficiency factor 1, and all these parameters we can use for designing. Now what I
have to find is effective gasket seating width as we have computed in last example. We have to
choose the optimum bolt or suitable bolt among these flange outside diameter and flange
thickness.
(Refer Slide Time: 25:12)

So let us start the part one of this. Before starting solution of this, we have summarized here a
few parameters as outer diameter pointed, design pressure is given as 2.5 meganewton per meter
square, allowable stress of shell and flange are given as 120 and 130 meganewton per meter
square respectively. Now allowable stress of bolt at atmospheric temperature and that at design
temperature.
(Refer Slide Time: 25:43)

So if you remember the problem we are given material for bolt, and that is IS:2002-1962 2A,
okay. And in this case design temperature is 400, okay. So 7.4 would be the allowable stress of
bolt material at design temperature. And here 9.6 will be considered as allowable stress of bolt
material at atmospheric temperature because value at lesser temperature than 250 is not available
in this table.
(Refer Slide Time: 26:20)

And further if you consider the gasket material we are given soft aluminum solid flat metal as
gasket material and corresponding to this I am having 4 as value of m and 61 as seating stress
and 6 is the actual minimum width of the gasket, okay. So all these values I have taken over here
that is allowable stress at design temperature 7.4 at atmospheric pressure 9.8 and this is the
conversion because if you remember these values are in kg force per mm 2.

So conversion of this 2 meganewton per meter square is 9.8067 and that value I have converted
and respective value are given over here in meganewton per meter square, and y we have taken
from gasket table, which is 61 and m we can consider as 4, so d i/D o is 1.02, other parameters
are you can see from the example.
(Refer Slide Time: 27:34)
So effective gasket width again I have to find d i because I know d i/D o as 1.02, so here this is
the value of d i, d o/d i you can find by this expression and then d o I can find as 0.83677.
Minimum gasket width is found as 0.01038, it means 10.38 mm and which has to compare with
the value given in the table and that is 6 [Link] among these we can consider as minimum
gasket width, which is 10.38 mm.

Now outer diameter of gasket will not be changed as whatever we have computed value of N that
I have taken as it is. So it will be equal to the previous value. Basic gasket width I can find as B
o and that should be N/2 if you remember because I have considered plain face. And further
based on B o as it is coming less than 6.3 mm I can calculate effective gasket width equal to B o
and which comes out as 0.00519, and further we can calculate G that is the diameter of reaction
of load in gasket and which comes out as 0.82638.
(Refer Slide Time: 29:09)
Now I have to choose the suitable bolt among these, okay. For that purpose I have to calculate
the bolting area and that we can calculate by operating condition as well as bolting-up condition.
So for operating condition this W o comes as 1.6094, H and H p we can find as we have
discussed in the last example. W g we can consider as 0.8177. Based on that we can find out
area for operating condition and area for bolting-up condition.

So based on these values I can find area at operating condition and bolting-up condition. So at
operating condition it is equal to 1.6096/72.569, which is the conversion of 7.4 kg force per mm
2, which is the allowable stress at design temperature and the area comes out as 0.0222. In the
similar line A g I am having as this 0.8218/96.108 and which comes out as 0.0086. Larger value
among these I have to choose as bolting area and that I can take as 0.02218, okay. And then
considering this bolting area and root area corresponding to these bolts, I can calculate minimum
number of bolts as we did in last example.

Now next multiple of 4 of all these values are given here, okay. And then R and B s I can see
from the bolt table and then considering these values we can calculate C 1 and C 2 and difference
of C 1 and C 2 we can find and which is found positive and minimum for 24 x 2.
(Refer Slide Time: 31:15)
So 24 x 2 can be chosen as suitable bolt or optimum bolt and corresponding value of C 2 I can
choose as bolt circle diameter, which comes out as 0.91245 for 24 x 2 bolt, okay. And then
flange diameter I can calculate as 0.95645 meter which is basically C + bolt diameter, that is
24/1000, which is already written over here plus 0.02, so that should be 0.01 x 2 because in this
case the value is not known to me so I will take 10 mm as minimum value which is basically
recommended minimum value for design of flange.
(Refer Slide Time: 32:11)

So considering all these values I can find out flange diameter as this. And then I have to find out
flange thickness and for that purpose I have to calculate flange moment. So for that I have
calculated W 1, W 2, W 3 and a 1, a 2, a 3 as we did in last example and then we can find out
moment at operating condition and similar moment at bolting-up condition. So controlling M
would be larger from these two and that is given for bolting-up condition, okay.

Now K I have taken as A/B, which is this and then Y I can calculate as 10.9677, Mue 0.3 I can
take, further C f I will take as 1 and then we can calculate thickness of flange which comes out as
0.0988 meter. Revised value of B s I have to take as 0.089 and considering this B s value I will
find out C f and then I can calculate revised value of t and in the similar line I keep on moving to
calculate the thickness of t.
(Refer Slide Time: 33:05)

So in that way we can calculate the thickness of flange and then we can complete the design of
flanges. So here we have solved two examples for design of flanges and I hope the method is
clear to you and here I am having some of the references to study about design of flanges and
here we will summarize the video and in this video we will summarize for lecture 2, 3, 4 and 4 of
week 3 because all these lectures were devoted to design of flanges, okay.
(Refer Slide Time: 33:42)
So summary goes as flange is defined along with its utility. Types of flanges and its facings are
discussed. Gaskets, its types and selection of it are discussed. Bolt load, its area and dimensions
are discussed. Design of flange considering operating condition as well as bolting-up conditions
are discussed. And then we have solved few examples with detail steps for design of flange.
That is all for now, thank you.