Hello!
I´m using CodeCalc for the first time in order to analyze a flange by the Appendix 2 of ASME VIII Division I.
As it´s the first time I decided to check the results by calculating the design manually.
So when I compare both results, everything is OK unless the STRESS FACTORS (Alpha, Beta, Delta, Lambda) values.
By using CodeCalc results the stresses in both assembly and operating conditions go too high while calculating manually the results seem to be more realistic.
My question is:
- does code CodeCalc aplly any stress intensity factor or maybe should I set up anything different?
Thanks in advance!
Above follows CodeCalc results. Please note that my problem is only about the STRESS FACTORS in the end.
Input Echo, Flange Item 1, Description: Flange Donato
Description of Flange Geometry (Type) Integral Weld Neck
Description of Flange Analysis Analysis Only
Design Pressure P 60.50 MPa
Design Temperature 120.00 C
Corrosion Allowance ci 1.6000 mm
Use Corrosion Allowance in Thickness Calcs. Yes
Flange Inside Diameter B 155.500 mm
Flange Outside Diameter A 550.000 mm
Flange Thickness t 31.7500 mm
Thickness of Hub at Small End g0 31.7500 mm
Thickness of Hub at Large End g1 76.2500 mm
Length of Hub h 191.0000 mm
Perform thickness calcs. based on rigidity Yes
Flange Material (Not Normalized)
Flange Allowable Stress At Temperature Sfo 324.000 MPa
Flange Allowable Stress At Ambient Sfa 345.000 MPa
Bolt Material SA-193 B7
Bolt Allowable Stress At Temperature Sb 172.375 MPa
Bolt Allowable Stress At Ambient Sa 172.375 MPa
Diameter of Bolt Circle C 438.200 mm
Nominal Bolt Diameter dB 50.8000 mm
Type of Thread Series TEMA Thread Series
Number of Bolts n 12
Compute Full Flange Design Bolt Load (S*ab) ? No
Flange Face Outside Diameter Fod 305.000 mm
Flange Face Inside Diameter Fid 155.500 mm
Flange Facing Sketch Code Sketch 6
Gasket Outside Diameter Go 290.520 mm
Gasket Inside Diameter Gi 268.280 mm
Gasket Factor, m 6.5000
Gasket Design Seating Stress y 180.000 MPa
Column for Gasket Seating 1, Code Column I
Contact Width of the Mettalic Ring w 14.8100 mm
Shell Material
Shell Allowable Stress At Temperature So 324.000 MPa
Shell Allowable Stress At Ambient Sa 345.000 MPa
Full face Gasket Flange Option Program Selects
ASME Code, Section VIII, Division 1, 2011a
Hub Small End Required Thickness due to Internal Pressure:
= (P*(D/2+Ca))/(S*E-0.6*P) per UG-27 (c)(1)
= (60.50*(155.5000/2+1.6000))/(324.00*1.00-0.6*60.50)+Ca
= 18.2864 mm
Flange analysis, Flange number 1, Description: Flange Donato
ASME Code, Section VIII, Division 1, App. 2, 2011a
Corroded Flange Thickness, tc = T-ci 30.150 mm
Corroded Flange ID, Bcor = B+2.0*ci 158.700 mm
Corroded Large Hub, g1cor = g1-ci 74.650 mm
Corroded Small Hub, g0cor = g0-ci 30.150 mm
Code R Dimension, R = ((C-Bcor)/2)-g1cor 65.100 mm
Gasket Contact Width, N = (Go-Gi) / 2 11.120 mm
Basic Gasket Width, b0 = w / 8.0 1.851 mm
Effective Gasket Width, b = b0 1.851 mm
Gasket Reaction Diameter, G = (Go+Gi) / 2.0 279.400 mm
Basic Flange and Bolt loads:
Hydrostatic End Load due to Pressure[H]:
= 0.785 * G * G * Peq
= 0.7854 * 279.4000 *279.4000 *60.5000
= 3709036.500 N
Contact Load on Gasket Surfaces[Hp]:
= 2 * b * PI * G * m * P
= 2 * 1.8513 * 3.1416 * 279.4000 * 6.5000 * 60.50
= 1277918.500 N
Hydrostatic End Load at Flange ID[Hd]:
= 0.785 * Bcor * Bcor * P
= 0.785 * 158.7000 * 158.7000 *60.5000
= 1196636.250 N
Pressure Force on Flange Face[Ht]:
= H - Hd
= .37090E+07 - .11966E+07
= 2512400.250 N
Operating Bolt Load[Wm1]:
= H + Hp + H'p (cannot be < 0)
= ( .37090E+07 + .12779E+07 + 0 )
= 4986955.000 N
Gasket Seating Bolt Load[Wm2]:
= y * b * PI * G + yPart * bPart * lp
= 180.00*1.8513*3.141*279.400+0.00*0.0000*0.00
= 292467.062 N
Required Bolt Area[Am]:
= Maximum of Wm1/Sb, Wm2/Sa
= Maximum of .49870E+07 / 172 , 292467 / 172
= 28933.3 mm^2
ASME Maximum Circumferential Spacing between Bolts per App. 2 eq. (3) [Bsmax]:
= 2a + 6t/(m + 0.5)
= 2 * 50.800 + 6 * 30.150 /(6.50 + 0.5)
= 127.443 mm
Actual Circumferential Bolt Spacing [Bs]:
= C * sin( pi / n ) )
= 438.200 * sin( 3.142 / 12 )
= 113.415 mm
ASME Moment Multiplier for Bolt Spacing per App. 2 eq. (7) [Bsc]:
= max( sqrt( Bs/( 2a + t )), 1 )
= max( sqrt( 113.415 /( 2 * 50.800 + 30.150 )), 1 )
= 1.0000
Bolting Information for TEMA Imperial Thread Series (Non Mandatory):
-----------------------------------------------------------------------------
Minimum Actual Maximum
-----------------------------------------------------------------------------
Bolt Area, mm^2 28933.311 20531.570 Failed
Radial distance bet. hub and bolts 63.500 65.100
Radial distance bet. bolts and the edge 50.800 55.900
Circumferential spacing between bolts 107.950 113.415 127.443
-----------------------------------------------------------------------------
Min. Gasket Contact Width (Brownell Young) [Not an ASME Calculation]:
= Ab * Sb/(y * PI * (Go+Gi) )
= 20531.570 * 172.38 /(180.00 * 3.14 * (290.52 + 268.28 ) )
= 11.200 mm[Note: Exceeds actual gasket width, 11.120 ]
Flange Design Bolt Load, Gasket Seating[W]:
= Sa * ( Am + Ab ) / 2.0
= 172.38 * ( 28933.3105 + 20531.5703 ) / 2.0
= 4262892.00 N
Gasket Seating Force[Hg]:
= Wm1 - H
= .49870E+07 - .37090E+07
= 1277918.75 N
Moment Arm Calculations:
Distance to Hub Large End[R]:
= (C - Bcor) / 2 - g1cor
= (438.200 - 158.700 ) / 2 - 74.650
= 65.1000 mm
Distance to Gasket Load Reaction[hg]:
= (C - G ) / 2.0
= ( 438.2000 - 279.4000 ) / 2.0
= 79.4000 mm
Distance to Face Pressure Reaction[ht]:
= ( R + g1cor + hg ) / 2.0
= ( 65.1000 + 74.6500 + 79.4000 ) / 2.0
= 109.5750 mm
Distance to End Pressure Reaction[hd]:
= R + ( g1cor / 2.0 )
= 65.1000 + ( 74.6500 / 2.0 )
= 102.4250 mm
Summary of Moments for Internal Pressure:
Loading Force Distance Bolt Corr Moment
End Pressure, Md 1196636. 102.4250 1.0000 122615160. N-mm
Face Pressure, Mt 2512400. 109.5750 1.0000 275407872. N-mm
Gasket Load, Mg 1277919. 79.4000 1.0000 101507880. N-mm
Gasket Seating, Ma 4262892. 79.4000 1.0000 338610848. N-mm
Total Moment for Operation, Mo 499530912. N-mm
Total Moment for Gaket Seating, Ma 338610848. N-mm
Effective Hub Length, ho = SQRT(Bcor*g0cor) 69.172 mm
Hub Ratio, h/ho = h / ho 2.761
Thickness Ratio, g1/g0 = (g1cor/g0cor) 2.476
Flange Factors for Integral Flange:
Factor F per 2-7.2 0.612
Factor V per 2-7.3 0.070
Factor f per 2-7.6 1.000
Factors from Figure 2-7.1 K = 3.466
T = 1.104 U = 1.798
Y = 1.636 Z = 1.182
d = .16183E+07 mm ^3 e = 0.0088 mm ^-1
Stress Factors Alpha = 1.267
Beta = 1.356 Gamma = 1.147
Delta = 0.017 Lambda = 1.164
Longitudinal Hub Stress, Operating[Sho]:
= ( f * Mo / Bcor ) / ( Rlambda * g1cor² )
= ( 1.0000 *.49953E+09 / 158.7000 ) / ( 1.1639 *74.6500² )
= 485.2 MPa
Longitudinal Hub Stress, Seating[Sha]:
= ( f * Ma / Bcor ) / ( Rlambda * g1cor² )
= ( 1.0000 * .33861E+09 / 158.7000 ) / ( 1.1639 * 74.6500² )
= 328.9 MPa
Radial Flange Stress, Operating[Sro]:
= ( Beta * Mo / Bcor ) / ( Rlambda * t² )
= ( 1.3555 *.49953E+09 / 158.7000 ) / ( 1.1639 *30.1500² )
= 4031.7 MPa
Radial Flange Stress, Seating[Sra]:
= ( Beta * Ma / Bcor ) / ( Rlambda * t² )
= ( 1.3555 *.33861E+09/158.7000 ) / ( 1.1639 *30.1500² )
= 2732.9 MPa
Tangential Flange Stress, Operating[Sto]:
= ( Y* Mo / (t² * Bcor) ) - Z * Sro
= ( 1.6363 *.49953E+09 / (30.1500² *158.7000 ) ) - 1.1816 *4031
= 900.3 MPa
Tangential Flange Stress, Seating[Sta]:
= ( Y * Ma / (t² * Bcor) ) - Z * Sra
= ( 1.6363 *.33861E+09 / (30.1500² *158.7000 ) ) - 1.1816 *2732
= 610.2 MPa
Average Flange Stress, Operating[Sao]:
= ( Sho + MAX( Sro, Sto ) ) / 2
= ( 485 + MAX( 4031 , 900 ))/ 2
= 2258.4 MPa
Average Flange Stress, Seating[Saa]:
= ( Sha + MAX( Sra, Sta ) ) / 2
= ( 328 + MAX( 2732 , 610 ))/ 2
= 1530.9 MPa
Bolt Stress, Operating[Bso]:
= ( Wm1 / Ab )
= ( .49870E+07 / 20531.5703 )
= 242.9 MPa
Bolt Stress, Seating[Bsa]:
= ( Wm2 / Ab )
= ( 292467 / 20531.5703 )
= 14.2 MPa
Stress Computation Results:
Operating Gasket Seating
Actual Allowed Actual Allowed
Longitudinal Hub 485. 486. 329. 518. MPa
Radial Flange 4032. 324. 2733. 345. MPa
Tangential Flange 900. 324. 610. 345. MPa
Maximum Average 2258. 324. 1531. 345. MPa
Bolting 243. 172. 14. 172. MPa
WARNING: Stress > Allowable Stress!
Estimated M.A.W.P. ( Operating ) 4.86 MPa
Estimated M.A.W.P. ( Gasket Seating ) -29.87 MPa
Estimated Finished Weight of Flange 1043.4 N
Estimated Unfinished Weight of Forging 3700.6 N
Flange Rigidity Index, Seating (rotation check) per APP. 2 [Js]:
= 52.14 * Ma / Bsc * Cnv_fac * V / ( Lambda * Eamb * go^(2) * ho * Ki )
= 52.14 * .33861E+09 / 1.0000 * 1.000 * 0.070 / ( 1.164 * 202713 *
30.150 ^(2) * 69.172 * 0.300 )
= 0.277 (should be <= 1)
Flange Rigidity Index Operating (rotation check) per APP. 2 [J]:
= 52.14 * Mo / Bsc * Cnv_fac * V / ( Lambda * Eop * goc^(2) * ho * Ki )
= 52.14 * .49953E+09 / 1.0000 * 1.000 * 0.070 / ( 1.164 * 196921
* 30.150 ^(2) * 69.172 * 0.300 )
= 0.421 (should be <= 1)
Minimum Design Metal Temperature Results :
Impact Test Temperature provided per Specification -18 C
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