Analysis of Flange Joints Under

W. J. Koves
UOP,
External Loads
25 East Algonquin Road, Flange joint leakage is one of the common maintenance problems in refineries and
P.O. Box 5017,
Des Plaines, IL 60017-5017
chemical plants. This paper studies the effect of external loads on the strength and
leakage behavior of flanged joints. Finite element and analytical methods are com-
pared, and the proposed method is compared with leakage data. The common ' 'equiv-
alent pressure" method is shown to be very conservative, and a method of evaluating
external loads is recommended.

Introduction more accurate than the rules of thumb. However, the method
still lacks the accuracy necessary to properly evaluate the ade-
The flanged joint is a complex, statically redundant, nonlin-
quacy of a flange joint under external loads.
ear, three-dimensional structural system (eg., Soler, 1980). The
The equivalent pressure is computed as the pressure that gives
large number of variables that affect the behavior of a bolted
the same maximum longitudinal stress in the flange neck as the
joint are too numerous to review here, and the reader is referred
applied external forces. The equivalent pressure for an applied
to books on the subject for a discussion of the variables involved
force, FA, and moment, M, is given by Eq. (2), where G is the
(Bickford, 1981). This paper addresses one aspect, the linear
gasket diameter and consistent units are used (Kellogg, 1956)
behavior of flanged joints under pressure and external loads, of
the design of bolted joints.
P M +
- =^ ^ (2)
Traditional Approaches
The equivalent pressure is then added to the design pressure,
Because of the complexity of a flange-joint system, pressure
and the flange adequacy for the total pressure is determined by
vessel and piping design engineers have used a variety of simpli-
either one of these approaches:
fied approaches to evaluate the adequacy of flanged joints under
external loads. • Comparison with the ANSI B16.5 flange ratings
• Computation in accordance with the ASME BPV Code Sec-
A Guidelines. General guidelines, more commonly re-
tion VIII design rules
ferred to as "rules of thumb" and normally expressed in terms
of a maximum force or moment as a function of diameter, were Although the ASME Code computation is the more accurate
used to determine if the loads resulting from external piping approach, the results are still conservative because the design
were excessive. Although these rules of thumb were simple to requires an artificially high pressure and the required bolt load
apply, they were also inaccurate. However, these types of rules to prevent gasket leakage is proportional to this pressure.
are still used to limit loads on pressure vessel nozzles or on
rotating equipment, such as pumps and compressors. D Equivalent Axial Force Method. A relatively simple
but effective method is to compute the maximum axial stress
B Bolt Stress Limits. The maximum force per bolt, as a in the flange neck that results from bending and axial forces.
result of pressure and external loads, is computed, neglecting The flange is then analyzed by using the ASME procedure and
the gasket reaction, and limited to a prescribed allowable. A adding an axial, axisymmetric force equivalent to the maximum
variation of this method has been in the ASME B31 MDC longitudinal stress being distributed 360 deg around the flange.
(Mechanical Design Committee) document for many years. Moments can be converted into an equivalent axial force, on
The maximum external moment to avoid leakage is given by the basis of gasket diameter, by Eq. (3)
Eq. (1)
AM
F = (3)
M,= (SbAb - PAP) (1) 1
eq

This method gives reasonable answers and has been effec-

where tively employed (Blick, 1950b; and Rodabough and Moore,
1976).
ML moment to produce flange leakage (in-lb)
C bolt circle diameter (in.) E Gasket Reaction. Another approach is to look at the
sb bolt stress (psi) reaction forces on the gasket alone, assuming that the bolt stress
Ah total bolt area (in. 2 ) remains unchanged with external loads (Blick, 1950a). The
P internal pressure (psi) validity of this assumption on the bolt stress is, of course, depen-
A„ area to outside of gasket contact (in. 2 ) dent on the stiffness of the gasket relative to the bolts. The shift
in neutral axis is computed on the basis of the loading and
C The Equivalent Pressure Method. The equivalent unloading properties of the gasket.
pressure method is the most common method of accounting for The problem with this method is that it is really applicable
external loads. The method is simple to apply and directionally only to flanged joints under low internal pressures. If the pres-
sures are high, the compression side never overcomes the reduc-
tion in gasket stress as a result of pressure, and the gasket stress
Contributed by the Pressure Vessels and Piping Division for publication in the remains on the same unloading gasket curve.
JOURNAL OF PRESSURE VESSEL TECHNOLOGY. Manuscript received by the PVP
Division, December 8, 1994; revised manuscript received June 27, 1995. Techni- Blach and Liguo (1992) compute the gasket reaction assum-
cal Editor: S. Y. Zamrik. ing that the bolts carry the tensile portion and the gasket carries

Journal of Pressure Vessel Technology FEBRUARY 1996, Vol. 1 1 8 / 5 9

Copyright © 1996 by ASME

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 Fig. 2 Equivalent force system on flange

Fe = F0 cos 9 (lb/in.)

Ms = M0 cose (in-lb/in.) (5)

These distributed loads are equivalent to the external applied

moment, MT, about the y-axis and the reacting force and mo-
Fig. 1 Flange reacting external moment
ment resulting from the bolting. Therefore, these distributed
loads (Fig. 2) must be in equilibrium.
Referring to Fig. 2 and summing moments about the y-axis
compression, ignoring pre-load and unloading of the gasket and
bolts. £M, = 0
F Finite Element Method. The finite element method
p2" HV
has the capability of analyzing a flange joint under pressure and
external loads by either a full three-dimensional model or an I Fg(r cos 9)rde - Me cos 9rde = 0
Jo Jo
axisymmetric model with moment loads applied as a single
harmonic term. Nonlinear gasket properties and thermal effects
can also be included. This method is one of the most accurate. I F0r2 cos 2 0d„ - M0 cos 2 9rde = 0 (6)
However, it is also the most time-consuming. Jo Jo

G Recommended Approach. The most efficient ap- Integrating and simplifying produces the simple result
proach for evaluating leakage is to evaluate the flange as a
structural system. The flexibility of the flange gaskets and bolts Mo = rFQ (7)
must be modeled to accurately predict the gasket and bolt loads
Next, the internal forces reacting the external loads, Fe and
resulting from pressure and external loads. The flange can be
Me are considered. On any plane section through the flange, at
analyzed by using the shell and plate theory solution by Waters
angle 9, the integrated normal and shear stresses result in a set
et al. (1951), which is consistent with the current ASME Code
of internal forces: Vs representing transverse shear, Te for tor-
approach.
sion, and me for internal moment.
The effect of axial loads on a flange joint can be handled the
Referring to Fig. 3 and using the symmetry boundary condi-
same as the axial pressure thrust term in the current ASME
tions along the ;t-axis results in the following equilibrium equa-
method. The axial force is simply added to the axial pressure
tions:
thrust force, and the ASME design procedure is followed for the
computation of flange moments. Using the ASME nomenclature
X My = Te cos 9 — ms sin 9 + Vsr cos 9
HD = 0.785B 2 P + FA (4)
where + I M0r cos 2 ada - I F0r2 cos 2 ada = 0 (8)
FA = axial applied force (lb)
P = design pressure (psi)
B = inside diameter of flange (in.)
HD = axial force in the flange neck (lb)
External moments are more difficult to handle. The loading
is not axisymmetric and cannot be addressed as easily as the
axial forces. However, the ASME design approach assumes
axisymmetric behavior. Therefore, the problem is to evaluate
the effect of external moment loading on the flange joint and
develop a correction to be applied to the axisymmetric analysis.
This will be addressed by analytically solving for the forces
acting on a ring flange, as a result of an external moment, and
then comparing with the axisymmetric force solution.
An external applied moment is assumed to create a linear
stress distribution in the flange neck. This moment can be re-
duced to a linear-distributed load, H'D (lb/in.), reacted by a
bolt load, F'B, and a gasket load, F'a, as shown in Fig. 1.
The flange system is approximated by a ring model with an
externally applied twisting moment, Me, and an external force,
Fg. The moment and force, both per unit length, vary with
angle, 9, as shown Fig. 3 Internal reaction forces

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 As a result of symmetry, the rotation about the x-axis is zero.
Therefore, the variation in strain energy is stationary.

= 0 (17)
dmRo

n nl2
f me dme
EI dmR
To_ dTe
GJ dmR
+ ky^^L]rd9
GA dmRa

Using Eqs. (10), (14), and (15) and substituting into Eq. (18)
=0 (18)

and integrating gives

J_ J_ F0r2
™«„ GJ
EI GJ

since M„ = F,,r

*it MQr
(19)
GJ
1 +
EI
Fig. 4 Axisymmetric 12-in. CL 150 flange
If applied force, H'D, in Fig. 1 were the result of an axisym-
metric axial load, the internal bending moment on the flange in
X Mx = mRa — Ver sin 9 — me cos 9 - Ts sin 9 terms of a uniform applied moment, M0, is (Cook and Young,
1985)

f
Jo
M0r cos a sin arfa
mro = rM0

+ I F0r2 cos a sin ada = 0 (9) Therefore, a moment correction factor, F , can be defined that
Jo adjusts for the torsional resistance of the flange to external
moment loads. Using the relationship between the shear and
X F, = - V , + f F 0 cos arrfa = 0 (10) elastic moduli
Jo
V„ = F o r s i n 0 (11) G =
2(1 + v)
Integrating and substituting Eq. (10) into Eq. (8) gives
gives
Te sin 6 = ^— {me sin 9 - F0r2 sin 9 cos 9) (12)
cos 0
F = (20)
Integrating Eq. (9) and simplifying by using the condition, M„
= Far, gives 1 +
2(1 + v)I
mRo - me cos 9 - Tg sin 9 - Ver sin 9 = 0 (13)
The greater the torsional resistance, relative to the bending
Substituting Eqs. (11) and (12) into Eq. (13) gives resistance, the less the induced circumferential bending stress
and corresponding flange rotation as a result of the external
me = mRa cos 9 (14) moment.
The foregoing equation is an exact solution for compact ring
and from Eq. (11) flanges, where bending is primarily carried by the ring. When
Te = mR(s sin 9 - F0r2 sin 9 (15) circumferential bending or flange rotation limits the design, the
equation may be applied directly. Finite element analysis of
Equations (11), (14), and (15) establish the internal forces loose ring flanges subjected to both an axisymmetric axial force
in terms of the applied external forces and the internal moment and a harmonically varying force agree with Eq. (20). Note
reaction, mRo, at the x-axis symmetry plane. that the correction can be significant, for example, a rectangular
The internal moment reaction, mRo, can be solved for by flange may be in error by a factor of two or more if the correc-
using an energy approach. The internal strain energy of one tion factor is not applied.
quadrant of the flange that was subjected to bending, shear, and A flanged joint is an elastically interacting system. The
torsion is as follows: flange, gasket, and bolt stiffnesses are analyzed as a system,
after being corrected for torsional stiffness. Integrating the har-
U r (Jd+ 2GJ y
2GA I
(16) monic reaction term gives
Jo \2EI

where Table 1 Flange rotation (deg)

E = modulus of elasticity Operating Applied
G = shear modulus Method Cold bolt-up pressure moment
I = bending moment of inertia
/ = polar moment of inertia Finite element 0.113 0.108 0.123
Theory 0.108 0.117 0.123
A = shear area

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 10"4 radians 10s Kg-M
7.3 14.6 21.8 29.1 2.3 7.6 6.9 9.2 11.5
700 —I 1 1— -r—
, , ,
o o y Test Data O S y »40000 psi
o Test Data /
-
600 - o o / - 4.14 Did Not Leak 6.90
Shell/Plate 0 /
Theory oo /

BOO o y - 6.52
'55
" o /
a
£ ° Of 2.76 4.14 2
= 400 0/
' CO Proposed
tn PO / 0L
£ Method
a. 2.76
o o / ™
"I 300 •

/a

200 ~ " 1.38 1.38

o /

100 - o -
00 / Pipe Bending Moment, 10° in-lb
i i _J
Fig. 6 Leakage pressures, 12-in.-CL 150 (305-mm) flanged joint
2.5 5 7.5 10
Flange Rotation, minutes
Fig. 5 Comparison of theory with experimental flange rotation data baugh in the discussion to Westrom and Burgh's (1951) paper,
and external moments, in accordance with the proposed method,
were also included. This analysis was performed with the K-
flange computer program.
MT (G2Ha,t + C2FBo) The finite element and analytical solutions for flange rotation
are compared for the cold bolt-up and operating conditions in
Table 1.
where The bolt stress was 40,000 psi (276 MPa) with an operating
pressure of 285 psi (1.97 MPa) and an external moment of
HG„ - gasket distributed load at 6 = 0 (lb/in.)
FB0 = bolt distribution load at 6 = 0 (lb/in.)
G, C = gasket, bolt diameters (lb/in.)

HG() and FBo are determined from the 3 X 3 stiffness matrix

for the flange, gasket, and bolting system, with the flange stiff-
ness corrected for the 3-D harmonic load.

Discussion
The analysis of flanged joints by the shell and plate theory
provided by Waters et al. (1951) has been used for many years
and is the basis for the ASME Code design rules. Equation (20)
may be used to obtain stress from the moment equilibrium
equation directly; however, the computation of leakage must
consider the flange flexibility to determine the most accurate
gasket-operating stress.
A 12-in. (305-mm) Class 150 B16.5 flange was selected, and
a finite element model of the geometry was developed. The
finite element model included pressure, axial, and moment
loads. Moment loads were accounted for by modeling as a
harmonically applied axial force to establish the three-dimen-
sional behavior. The ANSYS finite element computer code was
employed. A displaced stress contour plot of one of the load
cases is contained in Fig. 4.
The flange joint was also analyzed analytically by using the
Waters et al. (1951) solution for flange rotational flexibility
and modeling the flange, bolt, and gasket as a system (Westrom Pipe Bending Moment, 103 in-lb
and Burgh, 1951; Singh and Soler, 1983). The effects of pres-
sure rotation in accordance with the method proposed by Roda- Fig. 7 Leakage pressures, 3-in.-CL 150 (305-mm) flanged joint

62 / Vol. 118, FEBRUARY 1996 Transactions of the ASME

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 25,900 ft-lb (35,114 N-M). The finite element results were Acknowledgment
measured at the base of the flange and are in reasonable This paper is published with the permission of UOP and the
agreement with the theoretical results.
Materials Technology Institute.
Figure 5 compares the analytical solution for flange rotation
to test data for a 24-in. (610-mm) flange from the Oak Ridge
National Lab report by Rodabough and Moore (1976). The References
agreement is good; the analytical solution is on the conservative ANSYS, Swanson Analysis Systems, Houston, PA.
side of the test data. ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.
Bickford, J., 1981, An Introduction to the Design and Behavior of Bolted Joints,
Figure 6 compares the theoretical analysis based on Eq. (7) Marcel Dekker, Inc.
from Rodabaugh and Moore (1976), the analytical solution Blach, A. E., and Liguo, S., 1992, "Bolted Flanged Connections with Longitu-
proposed in this paper, and leakage test data from Rodabaugh dinal Bending Moments," ASME PVP-Vol. 235, Design and Analysis of Pressure
Vessels, Piping and Components.
and Moore (1976) and Tube Turns (1958), for a 12-in. CL Blick, R. G., 1950a, "Bending Moments and Leakage at Flanged Joints," Part
150 flanged joint. The equivalent pressure method (B16.5) is II, Petroleum Refiner, p. 385.
also included for reference. The computer program uses the Blick, R. G„ 1950b, "Bending Moments and Leakage at Flanged Joints," Part
gasket modulus recommended in by Rodabaugh and Moore III, Petroleum Refiner, p. 389.
(1976). The computer solution by Rodabaugh, et al. (ORNL- Cook, R. D., and Young, W. C , 1985, Advanced Mechanics of Materials,
MacMillian, New York, NY.
5035) gives results in between the two solutions plotted in Fig. Gould, H. H., and Mikic, B. B., 1972, "Areas of Contact and Pressure Distribu-
6. The K-Flange computer code based its leakage prediction on tion in Bolted Joints," ASME Journal of Engineering for Industry, Aug., p. 869.
when a very high leak rate was computed using the latest PVRC K-Flange, Pi Engineering Software, Hoffman Estates, IL.
gasket constants for compressed asbestos and an average gasket Kellogg, M. W., Company, 1956, Design of Piping Systems, John Wiley, New
York, NY.
stress over the width. All approaches assume a uniformly dis- Meek, H. R., 1969, "Analysis of Bolt Spacing For Flange Sealing," ASME
tributed average gasket stress and do not address the variability Journal of Engineering for Industry, Feb., p. 290.
of gasket stress between bolts, such as is discussed by Meek Roberts, I., 1950, "Gaskets and Bolted Joints," ASME Journal of Applied
(1969), Gould and Mikie (1972), and Roberts (1950). Mechanics.
Rodabaugh, E. C , and Moore, S. E., 1976, "Evaluation of the Bolting and
Figure 7 is a similar comparison for a 3-in. (75-mm) class Flanges of ANSI B16.5 Flanged Joints ASME Part A Design Rules," ORNL/
150 flange. The differences are even more pronounced. Sub/2913-C.
Rodabaugh, O'Hara and Moore, "Computer Program For the Analysis of
Flanged Joints With Ring-Type Gaskets," ORNL-5035, Oak Ridge National Lab-
oratory, Oak Ridge, TN.
Conclusions Singh, K. P., and Soler, A. I., 1983, "Design Parameters Affecting Bolt Load in
Ring-Type Gasketed Joints,'' ASME JOURNAL OF PRESSURE VESSEL TECHNOLOGY,
An analytical solution for a flange joint under external mo- Vol. 105, Feb., p. 11.
ment loadings was presented. The solution reduces to a rela- Soler, A. I., 1980, "Analysis of Bolted Joints with Non-linear Gasket Behav-
ior," ASME JOURNAL OF PRESSURE VESSEL TECHNOLOGY, Vol. 102, p. 249.
tively simple correction to the moment and allows it to be Tube Turns Report No. 2.033d, 1958, "Tests of Taper Face Welding Neck
treated as an axisymmetric axial force for ring bending. The Flanges under Gas and Hydrostatic Internal Pressure With and Without External
effects are significant and depend on geometry. Bending Moment," May 21.
Flange jointflexibilitywas included in the analytical model, Waters, E. B., Rossheim, D. B., Westrom, D. B., and Williams, F. S. G., 1951,
"Development of General Formulas for Bolted Flanges," Taylor Forge and Pipe
and the results compared with leakage data. The comparison Works Publication.
demonstrates the conservatism of the equivalent pressure Westrom, D. B., and Burgh, S. E., 1951, "Effect of Internal Pressure on Stresses
method. and Strains in Bolted-Flanged Connections," TRANS. ASME.

Journal of Pressure Vessel Technology FEBRUARY 1996, Vol. 1 1 8 / 6 3

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