th

V International Symposium on “Fusion of Science & Technology”,

New Delhi, India, January 18-22, 2016

ID: 2016-ISFT-430

Design and Optimization of Weld Neck

Flange for Pressure Vessel
Vinod Kumar1, Vivek Pratap Singh2, Surjit Angra3, Sushma Rani4
1,2,3,4
Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, India
1
[email protected]

Abstract: This paper presents the design analysis of a weld (FEA) to predict levels of stress and deflection of a
neck pressure vessel flange. Flanges are often used for particular flanged joint when the stud bolts are tightened and
applications where pressure is a factor. Flange data given flange pressurised. The level of stud bolt force selected must
in ASME B16.5 for flanges upto 24 inch and ASME B16.47 ensure the joint is sufficiently tight to avoid leakage.
for flanges greater than 24 inch. Rating for flanges is However, the force must not be excessive causing damage.
decided based upon design pressure & temperature limits Rachkow et. al. [1] studied the strength of the flange by
given in both codes. In our research, a model of the WNRF using basic design criteria and found the strength of the
is created in ANSYS and pressure is applied beyond the flange on given pressure. Modestova et.al. [2] studied the
given limit of pressures given in ASME B16.5. Stresses are different materials of the flange which provided more
calculated using mathematical approach and ANSYS pressure sustainability. Voloslin [3] study the added stress
software. This analysis reveals the zone of high localized on the flange due to the internal pressure and the bolt load.
stresses on the flange. The results obtained by both the Abid et. al. [4] studied the performance of a flange joint
methods are compared with allowable stress value for safe using different gasket under combined internal pressure and
& optimized designing. thermal loading. The FEA by David Heckman on pressure
vessel flange also suggest that the analyzing of the high
Keywords: ANSYS 15, Finite element analysis, Pressure stress area and different end connections have better result
vessel, Flange obtain if it is done by computer programme rather than hand
calculation.
1. INTRODUCTION
2. FLANGE DESIGN
Flanged joints on large diameter flanges can prove
problematic to seal successfully with many factors This study work has been carried out on the following
contributing to ensuring a successful operation. One such aspect
factor is stud bolt loading contributing to stress and
deflection of the flanged joint. Flanged joints with gaskets 1. To calculate the stresses by manual calculation.
are very common in pressure vessel and piping systems, and 2. To develop the FEM based model using ANSYS.
are designed mainly considering internal pressure.
Prevention of fluid leakage is the prime requirement of 3. To develop the geometry of flange using ANSYS.
flanged joints. Many design variables affect joint
performance and it is difficult to predict the behavior of 4. To compare the results of ANSYS and manual
joints in service. Nozzle and flange provide a way to calculation.
haulage of pressurised fluid. So it is very essential to
High-pressure flanges require a large bolt area to counteract
provide a leak proof and safe joint.
the large hydrostatic end force. Large bolts in turn increase
The flange structure itself is stressed due to this the design the bolt circle with a corresponding increase in the moment
of a flange and loads generated due to bolting, with or arm.
without flow of fluid. Usually flange is weld over the nozzle
Thicker flanges and large hubs are necessary to distribute
and makes a permanent joint and flanges are joined together
the bolt loads. A balance between the quantity and size of
by the nut and bolt. A flange joint is considered in two
bolts, bolt spacing, and bolt circle diameter is necessary. In
conditions first is initial and after tightening and in this study flange is designed by two approaches namely
operating condition. So that ASME gives the pressure design by rules & design by analysis.
criteria for different flange material. ASME VIII-1
Appendix 2 provides a method of sizing flanges. This Some of the principal assumptions and simplifications
investigation involves the use of finite element analysis involved in this method are summarized below [9]

ISBN: 978-93-84935-64-1 ♦ 608 ♦

 Design and Optimization of Weld Neck Flange for Pressure Vessel

1. Materials of all of the elements are assumed to be 2. Simulation of developed model to get the results
homogenous and remain elastic under the loading
conditions assumed in the design.
2. The effect of the bolt holes in the flanges is neglected.
3. Axial symmetry is used to reduce the problem to
consideration of the conditions on a single flange, hub
and shell cross section, and neglecting variations due
to location of bolts.
4. All loading applied to the flange is reduced to a
‘couple’ involving a pair of equivalent loads located at
the extremities of the flange.
5. Stretching of the middle surface of the flange ring due
to the applied couple is negligible.
6. Displacements of the joint are small such that the
theorems of superposition are valid.
Fig. 1. Pressure vessel weld neck flange.
7. When a ring moment is applied to the flange, the point
of connection between the flange and the hub is TABLE 3: Flange dimensional parameter [8]
assumed to have zero radial displacement.
Parameter Symbol Value
8. Hub and shell are assumed to act as thin shells.
Outside diameter of flange O 125
9. The inside bore of the hub and shell is used in the shell Diameter of the hub X 65
theory analysis instead of the mean thickness diameter.
Thickness of the flange Tf 15
10. Effects due to interaction of elements are neglected. Length of the weld neck Y 60
TABLE 1: Vessel design data Chamfer diameter of weld neck A 48.5
Weld neck diameter B 40.9
Parameter Symbol Value Unit
Design Pressure P 1.36E+05 N/m2 3.2 METHODOLOGY
Design Temperature T 200 °C
In this study the following methodology is adopted
Corrosion Allowance C 3 mm
Vessel or Nozzle Wall The Maximum stress on flange is calculated by the
thickness tn 16 mm mathematical approach.
Flange Thickness (Assumed) t 70 mm The analysis of strain in flange by varying pressure is the
area of research attention.
TABLE 2: Flange properties [7]

Parameter Value Unit

Material SA-105
Tensile Strength 485 MPa
Yield Strength 260 MPa
Max. Temperature Limit 583 °C
Density 7750 KG/M3
Modulus of Elasticity 185 GPa
Poisson Ratio 0.3

3. MATERIAL AND METHOD

3.1 MODELING PROCEDURE
1. Mathematical Procedure on the flange Fig. 2. Force represented on flange.

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18-22, 2016 ♦ 609 ♦
 Design and Optimization of Weld Neck Flange for Pressure Vessel

4. MATHEMATICAL APPROACH (DESIGN BY Moment arm for load HT=

RULES) hT=.5(C-B/2+hG) ……… (11)
Gasket contact width (N) = (Go-Gi)/22 ……..(1) =.5(80-40.9/2+11.625)
= (65-48.5)/2 =8.25mm = 15.8875

Basic gasket seating width (b0) =N/2 ……...(2) Moment arm for load HD=
= 8.25/2 hD=C-B/2 ……… .(12)
=4.125 =80-40.9/2
=19.55
Outside diameter of the gasket Contact area ………(3)
GC = if (GO ≤ Fod) TABLE 4: Force analysis of flange with force
GC =GO= 65mm Loading Force Distance Moment
Diameter at the location of the gasket load reaction N mm N-mm
G= (GC-2*b) ………. (4) End pressure (MD) 2803.07 19.55 54800.019
= 65-284.125 Face pressure(MT) 2805.93 15.8875 44579.212
= 56.75
Flange design moment for the operating
Total force work on the flange (Pe)
Pe = (16M/πG3+4PT/πG2+P) ………… (5) MO=(MD+MT)absolute ……. (13)
Here M=2000 N-mm =49689.61525 N-mm
PT=10000 N
Flange maximum operating stress
Pe=17.6
Pe=21.6 bar Smax=(1.33*t*e+1)*MO/(26.76*t2*B) (14)

Total hydrostatic end force Smax=

(1.33*15.9*.011*+1)*49689.61525/(26.76*15.92*40.9)
H= 78.5*G2*Pe ………(6)
= 78.58*56.752*1.86 = 221.352 N/mm2
= 5609 N 5. FINITE ELEMENT APPORACH (DESIGN BY
Contact load on flange surface ANALYSIS)
HP=2*b*π*G*m*Pe ……… (7) A model of flange is created in ANSYS and pressure and
Value of constant m=1 load are applied beyond the given limit of pressures and
thus study the finite element analysis of the flange. This
= 2*4.125* π*56.75*1*1.86
analysis reveals the zone of high localized stresses on the
=3846.1756 N flange. Different stress values were obtained corresponding
to the different pressures. All stresses were compared with
Total hydrostatic end force on the area inside the flange
allowable stress value and it has been optimized that how
HD=0.785*B2*Pe ……… (8) much pressure can be applied with same initial bolt load
=0.785*40.92*2.16 beyond the ASME pressure limit.
=2803.07N
5.1 BOUNDARY CONDITIONS AND MESH
Difference between the total hydrostatic force and end force SENSITIVITY ANALYSIS
on the area inside the flange
The boundary conditions for the flange of the pressure
HT=H-HD ………. (9) vessel are pressure applying on the inside diameter of the
=5609- 2803.07 flange and the chamfer weld neck is a constraint. The
=2805.93 movements in Z-axis directions of flange are given. The
other movements Uy = Ux = 0 of flange are zero, while the
Moment arm for load HG = boundary conditions of the flange are fixed. The movements
hG= C-G/2 …10) in all the three axes are constrained, Ux = Uy = Uz = 0. Force
is applied in the X direction on the flange. A mesh analysis
=80-56.75/2
is done on the FEA mode of flange, to ensure the optimum
=11.625 mesh size of FEA model for proper convergence and exact

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18-22, 2016 ♦ 610 ♦
 Design and Optimization of Weld Neck Flange for Pressure Vessel

numerical results. The maximum Von Mises stress value 491037 the mesh becomes appropriate and the number of
occurring in the FEA model is used as a convergence element reaches 340442, the meshing in the model of
criterion. The Fig. 4 Indicates that with the element number pressure vessel flange has enough sensitivity.

Fig. 3. Boundary Conditions of weld neck flange and Meshed finite element model of weld neck flange

5.2 FEA RESULTS 6. CONCLUSIONS

In this part, the results obtained gave a detailed distribution The Mathematical approach is used to design by rule and for
of stresses in the local part of the flange area. It is found that designing of pressure vessel the analytical method used is
the maximum intensity of stress is obtained near fixed finite element analysis and calculations is done as per
chamfered zone of the flange. The consequences of various Megyesy, (Pressure Vessel Handbook). The stress
design parameters on the calculated stress values are distribution over various geometric parameters of wear
investigated. The flange is suitable to withstand more plate, web plate, saddle, base plate and flange is analyzed
pressure value as per given in the ASME for same material. for the selection of optimal size of flange for given pressure
When pressure increase then the stress also increases and criteria. This signifies that the analytical method of
force which is applied to hold the flange also increases the designing is used to decide the safety pressure range in
flange stress. The stress distribution over various geometric ASME. The comparative study of these results helps to
parameters of wear plate, web plate, saddle, base plate and decide the most optimized design to fulfil the desired
flange is analyzed for the selection of optimal size of flange requirements and facilitates to find the economical solution.
for given pressure criteria. This signifies that the analytical After analysis of the result of the stress on the flange to
method of designing is used to decide the safety pressure greater pressure than as given in ASME for safe design, it
range in ASME. can be concluded that the weld neck flange is safe by
increasing the pressure value greater than the 13.6 bar given
in ASME. This flange can bear 18.4 bar pressure after
comparing the maximum stress to the allowable stress.
NOMENCLATURE:
hD: Radial distance from bolt circle to circle on which HD
acts(mm)
HD: Hydrostatic end force on area inside flange (N)
hG: Radial distance from gasket load reaction to bolt circle
(mm)
HG: Gasket load = Wm1- H for operating condition (N)
hT: Radial distance from bolt circle to circle on which HT
acts(mm)
HT: Difference between total hydrostatic end force and the
hydrostatic end force on area inside
flange = H-HD (N)
Fig. 4. Stress distribution over the flange. m: Gasket factor

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18-22, 2016 ♦ 611 ♦
 Design and Optimization of Weld Neck Flange for Pressure Vessel

y: Gasket / joint contact surface unit seating stress (MPa) pressure in vessel flanges, Journal of Chemical and
W: Design bolt load for the gasket seating condition (N) Petroleum Engineering, 1965, 1, 1, 16-19.
w: Width of the straight portion of obround flange (mm) [4] Khan, A.M.; Chattha, K.A.; Study the performance
bo: Basic gasket seating width (mm) of a flange joint using combined internal pressure
N: Gasket width (mm) and thermal loading, ASME PVP/ CREEP 8
G: Diameter at location of gasket load reaction (mm) conference, 2007, 1-7.
[5] David, H. Finite element analysis of pressure vessels,
REFERENCES
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[1] Rachkow, V.I.; Zusmanovskaya, S.I.; Gaponava, [6] ANSYS 15.0 Workbench
L.P. Calculation of low cycle strength for flange [7] ASME Boiler and Pressure Vessels Code Section II-
joint. Journal of Chemical and Petroleum Materials-Part D, 2013.
Engineering, 1994, 30, 6, 259-265. [8] ASME B16.5. Pipe flanges and flanged fittings,
[2] Modestova, R.V.; Gudkov, V.V.; Kasyanchek, G.I.; 2009.
Samofalov, O.P. Flange joints of vessel and [9] Singh K. P; Soler A. I. Mechanical Design of Heat
apparatus made of aluminum, Journal of Chemical Exchangers and Pressure Vessel Components,
and Petroleum Engineering, 1985, 21, 12, 572-573. Arcturus publishers, New Jersey, 1984, 1047.
[3] Voloshin, A.A. Added stresses due to the internal

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V International Symposium on “Fusion of Science & Technology”, New Delhi, India, January 18-22, 2016 ♦ 612 ♦