ANALYSIS OF BOLTED API FLANGE AND GASKET

Major Project
MECH4200-Simulation-Based Design
Department of Mechanical Engineering and Technology
Wentworth Institute of Technology
550 Huntington Ave, Boston, MA 02115

April 14, 2020

Nicholas Fornaciari
Professor: Dr. Xiaobin Le
 MECH4200 Simulation Based Design

Executive summary
This report aims to explore the validity of an API 2-1/16” 5M flange assembly, to
determine if the assembly shows signs of leakage under 5000 psi working pressure . It begins by
introducing background information on the need for standardized pipeline connections, the
proceeds to detail the design and geometry requirements for the specified flange. Next,
SolidWorks FEA simulation is utilized to simulate a flange assembly attached to a tank with
5000 psi working pressure. Assembly simplifications were used to reduce the complexity of the
simulation and streamline the computation. The outcome of this report is confirmation that an
API 2-1/16” 5M flange assembly will no leak under 5000 psi working pressure.

Table of Contents

EXECUTIVE SUMMARY .......................................................................................................... 2

CHAPTER 1: INTRODUCTION ................................................................................................ 3
CHAPTER 2: DESIGN REQUIREMENTS .............................................................................. 4
2.1 DESIGN................................................................................................................................... 5
CHAPTER 3: ANALYSIS ........................................................................................................... 8
3.1 DESCRIPTION OF CASE STUDIES AND BOUNDARY CONDITIONS ............................................. 8
3.2 FEA ANALYSIS................................................................................................................... 10
3.2.1 Pre-processing for FEA ............................................................................................... 10
3.2.2 FEA Results .................................................................................................................. 12
CHAPTER 4: DRAWINGS ....................................................................................................... 19
4.1 Bill of Materials for the API flange assembly. ................................................................ 19
4.2 Part Drawings................................................................................................................. 20
4.3 Assembly drawing ........................................................................................................... 23
CONCLUSION AND RECOMMENDATIONS ...................................................................... 24
REFERENCES............................................................................................................................ 25

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Chapter 1: Introduction
The American Petroleum Industry (API)1 was founded after World War I in 1919 to
establish a cooperation with the government while also promoting the petroleum industry in both
foreign and domestic trade. The reason the API was founded was because during World War I,
there were drilling delays due to shortages of equipment at drilling sites, due to the face that
there was no uniform size threads and couplings; one of the early efforts of API was to establish
these standards to increase oil production. The figure below (figure 1) shows pipelines which
conform to the API standards.

Figure 1. API Flange and Pipelines

The purpose of this project is to examine an API 5000 psi rated flange which connects a
tank at a rated pressure to a piping system in a petroleum plant. The tank can be assumed to be
fully rigid. The flange, gasket, and cap must be designed in Solidworks conforming to the API
standards for a 2-1/16” 5M assembly. The primary task is to investigate whether the specified
flange-gasket-cap assembly will leak or not, utilizing FEA.

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Chapter 2: Design Requirements

The API flange assembly consists of three components two flanges and a gasket. The
flange, composed of AISI 4130 Steel normalized at 870C, is the component which connects the
two pipes together, for this analysis since the tank is considered ridged a cap will be used rather
than a secondary flange. The cap follows the same geometry and material as the flange but is
closed in the middle unlike the flange. Between the flange and cap there is single gasket,
composed of AISI 316 Stainless Steel, which lays in the groove of each component. The flange,
cap and gasket, for a 2-1/16” 5M flange assembly, are connected by eight 1” bolts with nuts on
each side. The torque of tightening the bolts deforms the gasket and seals the assembly. The
image below (Figure 2) shows a general flange assembly for reference.

Figure 2. Reference Flange Assembly

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2.1 Design
For a 2-1/16” 5M flange assembly, conforming to API standards, the following drawings
from the WOODCO USA website fully define the entire assembly (Figures 3-5)[1]. The material
of the flange and cap was determined to be AISI 4130 Steel normalized at 870C. The material for
the gasket conforming to API standards was determined, from Figure 6, to be AISI 316 Stainless
Steel2. The configurations and loading conditions shown in Figure 3 - 7 are derived from
appropriate codes and standards. These include:
a) AMSME B16.5
b) ASTM A193 B7 (for bolting)
c) API Spec. 6A
d) API RP 5A3

Figure 3. Dimensions of 2-1/16" 5M Flange

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Figure 4. Dimensions of 2-1/16" RX 24 Gasket

Figure 5. Dimensions of 2-1/16" RX 24 Gasket

Figure 6. Gasket Materials List

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The source of loading in the flange assembly comes from the torque applied to the bolts.
The bolts tighten applying a compression force onto the assembly. Each flange configuration has
a specific minimum torque that must be applied in order to deform the gasket enough to seal. For
a 2-1/16” 5M flange assembly the minimum torque that must be applied is 319 FT*LBS as
shown in Figure 7.

Figure 7. Loading Conditions of the Flange Assembly

The Flange assembly has a total of 27 component which are outlined in the bill of
materials below, table 1.
Table 1. Bill of Materials

Item Quantity
Flange 1
Cap 1
Gasket 1
Bolt 8
Nut 16

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Chapter 3: Analysis
This section covers the specification of the flange loading conditions, boundary
conditions, FEA setup, results, and analysis of results.
3.1 Description of Case Studies and Boundary Conditions
In reference to standard API 6A the loading of the bolts for a 2-1/16” 5M flange assembly tis
319 FT*LBS as shown below in Figure 8. This torque will be transformed into an axial
preloading, as shown below using equation 1, on the bolts in order to accurately run the FEA.
The axial preload applied to the bolts will act as a compression force applied to the assembly in
the simulation by each bolt. The force is applied to seal the assembly in order to counter act the
5000 PSI of pressure running through the pipe to prevent leakage, as shown in free-body diagram
(Figure 9).

Figure 8. Loading Cases with Appropriate References to Codes / Standards

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𝑇 319 ∗ 12
𝐹= = = 19140 (𝑙𝑏)
𝐾𝑑 0.2 × 1
Equation 1. Axial Preloading from Given Torque

T=Tightening torque (lb-ins)

K=coefficient, 0.2
F=tightening axial load (lb)
d= nominal diameter of the bold
For 2-1/16” API flange
T=319(ft.lb)=319*12 (in*lb)
d= 1”
A summary of all of the forces in the assembly can be seen in the table below, Table 2.
Table 2. Summary of Forces

Summary of Forces
Bolt Preload Operational Proof Pressure Assembly Torque
Force [lb] Pressure Reaction Reaction Force [ft*lb]
Force [lb] [psi]
19140 Less than 5000 5000 319

Bolt with 19140 lb. Preloading

5000 PSI

Figure 9. Free Body Diagram of 1/8 of the Assembly

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3.2 FEA analysis

The FEA will utilize SolidWorks FEA package. Simplifications were made to the model in
order to reduce complexity and calculation time.

3.2.1 Pre-processing for FEA

Geometry: In order to reduce the complexity of the FEA two major simplifications were made
to the flange assembly. Since the flange assembly is completely symmetrical a small portion of
the model can be used to run the simulation and the results will be identical throughout the
model, it is assumed that the model loading and characteristics are completely uniform. With this
assumption a 1/8th portion of the model was used for the simulation. This 1/8th model included a
complete through hole for the bolt, as seen in Figure 10.

Figure 10. Simplified Assembly Model

Connectors: The second major simplification that was made to the simulation was the use of a
simulated bolt connector rather than a solid bolt. The simulated bolt adhered to the appropriate
standards, API 5A3 and ASTM A193 B7, and was used to further reduce complexity and
simulation time. The bolt was had a 1” diameter and was composed of alloy steel.

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Contact Sets: A contact set of no penetration was used at the interface between the flanges and
the gasket. This ensured the force was applied to the gasket rather than clipping the surface of the
flange through the gasket.

Fixtures: Since the flange would be welded to the tank during application, this model has a fixed
geometry on the top of the flange. Since symmetry can not be applied to this model because it is
only a 1/8th model, fixtures were applied to the internal flat faces of the flange, cap, and gasket to
prevent normal displacement. Fixing the internal surfaces with no normal displacement
effectively simulates a symmetry fixture. The fixtures can be seen in Figure 11 , the green arrows
denote the direction which displacement can not occur.

Figure 11. Simplified Assembly Fixtures

Loading: The internal load on the assembly is caused by the working pressure of the pipeline,
which is 5000 psi. The pressure is applied to all components in contact that are in contact with
the fluid, this loading is illustrated in Figure 9, where the red arrows indicate the surface and
direction the pressure is being applied.

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3.2.2 FEA Results

The result plots below illustrate the worst-case scenario, and indicate locations of the
highest stress and lowest factor of safety.

Figure 12. Von Mises Stress Plot of the Flange

Figure 13. Von Mises Stress Plot of the Gasket

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Figure 14. Von Mises Stress Plot of the Cap

Figure 15. Contact Pressure Plot of the Cap

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Figure 16. Contact Pressure Plot of the Flange

Figure 17. Contact Pressure Plot of the Gasket

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Figure 18 displays edges in contact with the gasket, each edge is colored and labelled. The graph
below figure 18 indicated the contact pressure of each of these edges the colors are correlated to those
in figure 18. For instance, the edge which is colored red and labeled edge 1 is the red line on the graph.

Edge 1 Edge 2

Edge 3 Edge 4

Figure 18. Edge Reference for Sealing Surface Contact Parametric Stress Plot

Figure 19. Sealing Surface Contact Parametric Stress Plot

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Figure 20. Resultant displacement of Flange Assembly

Figure 21. Factor of Safety less than 2 of Flange Assembly

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Figure 22. Factor of Safety less than 2 of Cap

Figure 23. Factor of Safety less than 2 of Gasket

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Figure 24. Factor of Safety less than 2 of Flange

Table 3. Results

Component Maximum Margin Minimum Maximum

Stress (Psi) Factor FOS Displacement
(in)
Flange 3.082*105 7.026 0.217 0.00244
Cap 3.118*105 7.712 0.214 0.07043
Gasket 4.186*105 7.026 0.059 0.00372

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Chapter 4: Drawings

4.1 Bill of Materials for the API flange assembly.

Figure 25. Bill of Materials

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4.2 Part Drawings

Figure 26.Detailed Engineering Drawing with Dimensions for Cap

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Figure 27.Detailed Engineering Drawing with Dimensions for Gasket

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Figure 28. Detailed Engineering Drawing with Dimensions for Flange

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4.3 Assembly drawing

Figure 29. Full Assembly Drawing

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Conclusion and Recommendations

In conclusion, this study proves that the flange assembly can endure the 5000-psi
working pressure and does not leak. The proof that the assembly does not leak is apparent in
Figure 19, which shows the contact pressure of each edge of the gasket, since the contact
pressure on each edge is far greater than the working pressure of 5000-psi. Any margin factor
above 1 means that the gasket will not leak, in the case of this assembly the lowest margin factor
was 7.026 meaning there is no chance of leakage. To further improve margin factor, it would be
recommended that a hole be placed in the middle of the gasket to increase expansion of the
gasket, thereby increasing contact pressure. This simulation was a great display of the
importance of simulation-based design, utilizing FEA techniques learned from class to validate
an API standard flange design.

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References
[1] “API,” Energy API. [Online]. Available: https://www.api.org/. [Accessed: 13-Apr-2020].

[2] “Safe to Use API Spec 6A, 16A, 17D Oilfield Pressure Control Equipment and 7K, API
Monogrammed Equipment, API Oilfield Products Supplier, for Flanges, Well Head and Drill
Through Equipment, WOODCO USA, For Sale. Load testing service, Rent API Test Flanges,”
Safe to Use API Spec 6A, 16A, 17D Oilfield Pressure Control Equipment and 7K, API
Monogrammed Equipment, API Oilfield Products Supplier, for Flanges, Well Head and Drill
Through Equipment, WOODCO USA, For Sale. Load testing service, Rent API Test Flanges.
[Online]. Available: https://www.woodcousa.com/. [Accessed: 09-Apr-2020].

[3] Richard G. Budynas and J. Keith Nisbett, Shigley’s Mechanical Engineering Design, page
416- 424, 10th edition, McGraw Hill Education, 2014.

[4] Mech4000 Major project 2020-v6-ind, Xiaobin Le

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