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I N D U S T R I A L P R O D U C T S A N D S E R V I C E SI N D U S T R I A L P R O D U C T S A N D S E R V I C E S
Flange Live Flange Live loading loading Ad anced Ad anced Technolog for Flange Technolog for Flange Flange Live Flange Live loading loading Ad anced Ad anced Technolog for Flange Technolog for Flange AdvancedAdvanced Technology for FlangeTechnology for FlangeSealingSealingAdvancedAdvanced Technology for FlangeTechnology for FlangeSealingSealing
FLMUG August, 2009Ron FrisardAW Chesterton
I N D U S T R I A L P R O D U C T S A N D S E R V I C E SI N D U S T R I A L P R O D U C T S A N D S E R V I C E S
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What are we going to cover??What are we going to cover??What are we going to cover??What are we going to cover??
Wh t i fl liWhat is flange live loading- How does it work- What we offer
Heat Exchangers
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Flange sealingFlange sealingFlange sealingFlange sealing
Correct gasket selectionProper bolting proceduresFlange Live Loading for critical flange sealing situationssealing situations
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Flange sealingFlange sealingFlange sealingFlange sealing
Correct gasket selectionProper bolting proceduresFlange Live Loading for critical flange sealing situationssealing situations
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Flange Sealing FactorsFlange Sealing FactorsFlange Sealing FactorsFlange Sealing Factors
Requirements for a sealed flangeRequirements for a sealed flange connection:- Compressibility gasketgasketCompressibility- Recovery (memory)- Temperature resistance
gasket gasket material material relatedrelatedTemperature resistance
- Chemical compatibilityrelatedrelated
flfl- Gasket seating stress flange flange connection connection
relatedrelated
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relatedrelated
FlangesFlangesFlangesFlanges
A process flangeA process flange connection is made up out of 2 flanges,out of 2 flanges, tightened together with bolts, with a gasket in bo ts, t a gas etbetween to seal any liquid from leaking out.qu d o ea g out
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FlangesFlangesFlangesFlanges
Flanges are not Flanges are not perfectly flat. perfectly flat.
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FlangesFlangesFlangesFlanges
The gasketThe gasketa compressible materiala compressible materialor a combination of or a combination of materialsmaterialsprevents leakageprevents leakage
i t t t th dii t t t th diresistant to the medium resistant to the medium being sealedbeing sealedable to withstand theable to withstand theable to withstand the able to withstand the application temperatures application temperatures and pressuresand pressures
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FlangesFlangesFlangesFlanges
A seal is effected A seal is effected by the action of by the action of yyforce upon the force upon the gasket surface. gasket surface.
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Forces On The GasketForces On The GasketForces On The GasketForces On The Gasket
Sufficient stress must i th k tremain on the gasket
surface to prevent leakage. PPleakage. PP
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Flange Sealing FactorsFlange Sealing FactorsFlange Sealing FactorsFlange Sealing Factors
How can we influence and maintain:How can we influence and maintain:- Compressibility- Recovery (memory)- Recovery (memory)- Temperature resistance- Chemical compatibilityp y
- By choosing the right gasket!
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Flange Sealing FactorsFlange Sealing FactorsFlange Sealing FactorsFlange Sealing Factors
How can we influence andHow can we influence and maintain:- Pressure resistance (friction & tensile
strength)- Gasket surface tension
- By having a good performing y g g p gflange connection!
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Stretch of the boltStretch of the boltStretch of the boltStretch of the bolt
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BoltingBoltingBoltingBolting
LL
HNHNLSGLSGLGLG D = Nominal DiameterD = Nominal Diameter
L = Nominal DiameterL = Nominal DiameterLSGLSG o e eo e eLBG = Length of BodyLBG = Length of BodyLC = Overall LengthLC = Overall LengthLG = Grip LengthLG = Grip Length
DD LT = Length of threadsLT = Length of threadsLSG = Length of threads LSG = Length of threads within gripwithin grip
i h f di h f d
HHHHLCLC
LTLTLBGLBGHH = Height of HeadHH = Height of HeadHN = Height of nut HN = Height of nut
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LCLC
Typical Elastic CurveTypical Elastic CurveTypical Elastic CurveTypical Elastic Curve
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Chesterton GlobalChesterton Global
BoltsBoltsBoltsBolts
A bolt is an elasticA bolt is an elastic elementWhen you tighten a bolt, you stretch ityou stretch itThe more you stretch it, the higher the bolt forceThe stretch of the bolt is FFThe stretch of the bolt is limited by the yield strengthIf you stretch the bolt
FF
If you stretch the bolt beyond this point the bolt will deform plastically
ΔΔllNuclear Power -18-Chesterton Global Training
p yΔΔll
Clamping LengthClamping LengthClamping LengthClamping Length
B ltBolt Clamping l th ththlength.
ampi
ng L
engt
ampi
ng L
engt
Distance from nut
Cl
Cl
centres.
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Young’s ModulusYoung’s ModulusYoung’s ModulusYoung’s Modulus
λ = σ / ε= Stress / Strain
(F/A) / ( /L)= (F/A) / (x/L)
Bolt Stretch x = FL/AλAverage bolt stretch / 100mm (3.94”) of g ( )bolt clamping length is 0,1mm (.003”).
10” f b lt 0076”Nuclear Power -20-Chesterton Global Training
10” of bolt ~ .0076”
Thermal Expansion/ContractionThermal Expansion/ContractionThermal Expansion/ContractionThermal Expansion/Contraction
xt = α . l . ΔTt
α = Co-eff of Thermal Expansione.g. 1,8 x 10-5 m/m.oC-1e.g. 1,8 x 10 5 m/m. C
Expansion / Contraction xt ≈ 0,18mm ( 007”) / 100mm (3 94”) length and(.007 ) / 100mm (3.94 ) length and 100oC (212oF)vs Average bolt stretch / 100mm (3 94”)vs Average bolt stretch / 100mm (3.94”) of bolt clamping length is 0,1mm
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(.003”).
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BoltsBoltsBoltsBolts
DN80 PN16 flangeDN80 PN16 flange8 bolts M16Normal bolts- Bolt stretch 0.003”
Stretch boltsB lt t t h 0 0043”- Bolt stretch 0.0043”
Extended bolts- Bolt stretch 0.0059”
Combination- Bolt stretch 0.0075”
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Basic Live loading principleBasic Live loading principleBasic Live loading principleBasic Live loading principle
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Bolt Load CurveBolt Load CurveBolt Load CurveBolt Load Curve
Yield pointYield pointe d poe d po
Yield StressYield Stress
Tensile StressTensile Stress
Target Bolt Target Bolt StressStress
Yield StressYield Stress
stic
Ran
gest
ic R
ange
Yield Stress for ASTM Yield Stress for ASTM A193A193--B7 Bolt 720 B7 Bolt 720 N/mmN/mm22 (105,000PSI)(105,000PSI)
Ela
Ela
30K Stress30K Stress
45K Stress45K Stress~ 310N/mm~ 310N/mm22 Bolt Stress at Spring Bolt Stress at Spring
Flat LoadFlat Load30K Stress30K Stress~ 207N/mm~ 207N/mm22
Elasticity Elasticity Increase (Safety Increase (Safety Factor) Factor)
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Deflection (mm)Deflection (mm)
Bolt Stretch Bolt Stretch (travel) Comparison(travel) ComparisonDIN Flange DN65 / PN 40DIN Flange DN65 / PN 40Bolt Stretch Bolt Stretch (travel) Comparison(travel) ComparisonDIN Flange DN65 / PN 40DIN Flange DN65 / PN 40
0035”0035”.0173”.0173”
.0023”.0023” .0035”.0035”
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ANSI 150 lbANSI 150 lbANSI 150 lbANSI 150 lb
NPS Bolt Spring Spring
MMMM MMMMNPS Bolt Spring Spring
(Inch) OD x ID Stretch Item Travel1/2 47 x 21 0.04 1201 0.283/4 57 x 27 0.05 1201 0.281 66 x 33 0.05 1201 0.28
1 1/4 76 x 42 0.06 1201 0.281 1/2 85 x 48 0.06 1201 0.28
2 104 x 60 0.07 1202 0.442 1/2 123 x 73 0.08 1202 0.44
3 136 x 89 0.08 1202 0.443 1/2 161 x 102 0.08 1202 0.44
4 174 x 114 0.08 1202 0.445 196 x 141 0.08 1203 0.486 222 x 168 0.09 1203 0.488 279 x 219 0.10 1203 0.4810 339 x 273 0 10 1204 0 51
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10 339 x 273 0.10 1204 0.5112 409 x 324 0.11 1204 0.51
ANSI 300 lbANSI 300 lbANSI 300 lbANSI 300 lb
MMMM MMMMNPS Bolt Spring Spring
(Inch) OD x ID Stretch Item Travel1/2 53 x 21 0.05 1201 0.283/4 66 x 27 0 06 1202 0 443/4 66 x 27 0.06 1202 0.441 73 x 33 0.06 1202 0.44
1 1/4 82 x 42 0.06 1202 0.441 1/2 95 x 48 0.07 1203 0.48
2 111 x 60 0 08 1202 0 442 111 x 60 0.08 1202 0.442 1/2 130 x 73 0.09 1203 0.48
3 149 x 89 0.10 1203 0.483 1/2 165 x 102 0.10 1203 0.48
4 180 114 0 10 1203 0 484 180 x 114 0.10 1203 0.485 215 x 141 0.11 1203 0.486 250 x 168 0.11 1203 0.488 307 x 219 0.13 1204 0.51
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10 361 x 273 0.15 1205 0.6812 422 x 324 0.16 1206 0.76
Chesterton Flange SpringsChesterton Flange SpringsChesterton Flange SpringsChesterton Flange Springs
Ch t t ’ fl liChesterton’s flange live loading is intended to
t f th lcompensate for thermal cycling effects by storing l tielastic energy
Stored elastic energy delays the loss of bolt stretch
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Bolt Stretch ComparisonBolt Stretch ComparisonANSI 24” 150lb Flange, 1ANSI 24” 150lb Flange, 1--1/4”Bolt, Length 6.750”1/4”Bolt, Length 6.750”Bolt Stretch ComparisonBolt Stretch ComparisonANSI 24” 150lb Flange, 1ANSI 24” 150lb Flange, 1--1/4”Bolt, Length 6.750”1/4”Bolt, Length 6.750”
55005500 5505H5505H--30K30K
5505H5505H--45K45K
5505H5505H--60K60K
Assembly Force 45,411 LbsAssembly Force 45,411 Lbs
Values Below for only one side of SpringsValues Below for only one side of SpringsDouble if springs on both sidesDouble if springs on both sides
0.0417 Inch0.0417 Inch0.0291 Inch0.0291 Inch
0.0240 Inch0.0240 Inch0 0208 I h0 0208 I hPlain boltPlain bolt
0.0078 Inch0.0078 Inch
Stretch boltStretch bolt
0.0102 Inch0.0102 Inch
0.0208 Inch0.0208 Inch
2.6X2.6X3X3X3.7X3.7X5.3X5.3X
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Poor Design due to frictional forcesPoor Design due to frictional forcesPoor Design due to frictional forcesPoor Design due to frictional forces
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Chesterton DifferentiationChesterton DifferentiationChesterton DifferentiationChesterton Differentiation
E i d S l tiEngineered SolutionFocus on the entire system
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Nuclear Power -33-ChestertonChesterton
Stud Load vs Temperature, E-1585B, Top Channel to Shell,During Cool Down
80 500
72
74
76
78
80
400
450
500
SL=Stud Load TI=Temperature
Sh Top Lt SLShell TI Sh Flange TITS Stud TI Tube Sh TICh Flange TI Channel TI
Feed Pulled, Wash-Oil In
64
66
68
70
72
d in
PS
I X 1
000
250
300
350
pera
ture
Ch Flange TI Channel TI
56
58
60
62
64
Stud
Loa
d
100
150
200
Tem
p
With springsWith springs
50
52
54
56
:30
:37
:44
:51
:58
:05
:12
:19
:26
:33
:40
:47
:54
:01
:08
:15
:22
:29
:36
:43
:50
:57
:04
:11
:18
:25
:32
:39
:46
:53
:00
0
50
100
Stud Load
Valley Effect
No springsNo springs
With springsWith springs
Nuclear Power -34-Chesterton Global TrainingApproximate situation with Springs applied. Residual Stud load remains higher thus Approximate situation with Springs applied. Residual Stud load remains higher thus preventing gasket failure and leakagepreventing gasket failure and leakage
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Time
70
72
74 Shell TI Sh Flange TITS Stud TI Tube Sh TICh Flange TI Channel TI
66
68
70
62
64
66
58
60
62
54
56
58
N iN i
With springsWith springs
50
52
54 Stud Load
Valley Effect
No springsNo springs
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50
13:3
013
:37
13:4
413
:51
13:5
814
:05
14:1
214
:19
14:2
614
:33
14:4
014
:47
14:5
415
:01
15:0
815
:15
15:2
215
:29
15:3
615
:43
15:5
015
:57
16:0
416
:11
16:1
816
:25
16:3
216
:39
16:4
616
:53
1700
Time
ChevronTexaco ChevronTexaco Metal Jacketed Gasket RelaxationMetal Jacketed Gasket RelaxationChevronTexaco ChevronTexaco Metal Jacketed Gasket RelaxationMetal Jacketed Gasket RelaxationMetal Jacketed Gasket RelaxationMetal Jacketed Gasket RelaxationMetal Jacketed Gasket RelaxationMetal Jacketed Gasket Relaxation
E-1585A Channel to Shell After 2 Cycles, Clad Gaskets
85A Chan to Shell 85A Ch/Sh 2 Cycles Initial Average Bolt Stress = 72,000
0.0015
00
0.0004 -0.0008120000
14000085A Chan to Shell 85A Ch/Sh 2 Cycles Initial Average Bolt Stress 72,000
Average After Cycles = 25,80064% Bolt Stress Loss
80000
100000
Stre
ss
40000
60000
Bolt
S
0
20000
1 4 7 0 3 6 9 22 25 28 31 34 37 40 43 46 49 52 55 58 61 64 67 70 73 76
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1 1 1 1 2 2 2 3 3 3 4 4 4 4 5 5 5 6 6 6 7 7 7
Bolt Number
Flange Live LoadingFlange Live LoadingFlange Live LoadingFlange Live Loading
Chesterton’s flange live loading is intended to compensate for thermal cycling effects byto compensate for thermal cycling effects by storing elastic energy.The use of Flange Live Loading resolvesThe use of Flange Live Loading resolves issues not considered in the various design codes ;codes ; - ASME, Stoomwezen, AD Merkblatt.
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Product highlight: 5500/5505H Flange Product highlight: 5500/5505H Flange springsspringsProduct highlight: 5500/5505H Flange Product highlight: 5500/5505H Flange springsspringsp gp gp gp g
5500 Flange springsMade of 17-7 pH stainless steel
5505H Flange springs5505H Flange springsM d f Hi h t th Ch iM d f Hi h t th Ch iMade of 17-7 pH stainless steel
Maximum flange temperature of 572°F (302°C)2 springs per side for B7 bolting
Made of High strength Chromium Made of High strength Chromium based Steelbased SteelMaximum flange temperature of Maximum flange temperature of 11001100°°F (595F (595°°C)C)
Come in one load rangeCan be made of special materials
11001100 F (595F (595 C) C) 1 springs per side1 springs per sideCome in three load ranges: Come in three load ranges: 30K,45K, and 60K30K,45K, and 60K
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30K,45K, and 60K30K,45K, and 60K
LIVELOADLIVELOADRECOMMENDED USAGERECOMMENDED USAGE
PROBLEM FLANGE APPLICATIONSPROBLEM FLANGE APPLICATIONS THERMAL CYCLING APPLICATIONSHEAT EXCHANGERSHEAT EXCHANGERSWHEN USING GASKETS WITH HIGH CREEP FACTORS
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Heat ExchangersHeat ExchangersHeat ExchangersHeat Exchangers
CRITICALPROBLEMATICLABOR INTENSIVELABOR INTENSIVENO INSTALLED SPARESSPARES
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THERMAL THERMAL --CAMERACAMERA
NORMAL CAMERANORMAL CAMERACAMERACAMERA
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Chesterton Critical Flange SealingChesterton Critical Flange SealingChesterton Critical Flange SealingChesterton Critical Flange Sealing
Engineering consolation on criticalEngineering consolation on critical flangesG k t d b lti d tiGasket and bolting recommendationsSealing stress calculationsFlange live loading recommendations
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Chicago Service CenterChicago Service CenterChicago Service CenterChicago Service Center
Traceable B7 bolting to specific cutTraceable B7 bolting to specific cut lengths P t ith L d S i l W dPartners with Leader Spiral Wound gaskets for standards and special
fi ticonfigurations
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Th kThanks you
Questions???Questions???Nuclear Power -44-44
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