Technical Review: Reciprocating Hydrogen Make-Up Compressor First

Stage Cylinder Head Cover Flange Stud Failures

By Abdulrahman Alkhowaiter August 2021

Fig-1: H2 Makeup Compressor Installed Jan-2018 Compressor 6.5 MW Rated

Introduction
The lube refining company 6.5 MW rated Hydrogen Make-up reciprocating compressor was started on 22, April, 2019 as switch over program.
After 3 days from the normal operation the field operator observed that 9 Studs sheared completely from 1st stage cylinder end cover. The
cover blowout could have caused a major gas explosion so was extremely dangerous. The compressor first stage end cover was opened recently
with the presence of compressor OEM and Samsung engineering to replace the packing & inspect the piston condition. The OEM and repair
contractor assembled the end cover bolts and claimed that they torqued them to 375 NM as per vendor recommendation. Also, the vibration
was checked in advance without any abnormal finding. This compressor has only been in service for 12 months operation.

Fig-2: First Stage Cylinder Head with Broken Studs, Nine Out Of 24 Studs Failed Under Normal Operation.

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Technical Review: Reciprocating Hydrogen Make-Up Compressor First
Stage Cylinder Head Cover Flange Stud Failures
By Abdulrahman Alkhowaiter, Machinery Consultant, August 2021

Fig-3: Sectional Drawing First Stage Cylinder Showing Failed Cylinder Cover Flange

Fig-4: View of Failed Studs on First Stage. All Failed Studs X-section Display Fatigue Failure Evidence.

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Technical Review: Reciprocating Hydrogen Make-Up Compressor First
Stage Cylinder Head Cover Flange Stud Failures
By Abdulrahman Alkhowaiter August 2021

Review of First Stage Cylinder Head Flange Cover Bolted Joint Design

Fig-5: Bolt or Stud loading on Flange: Principles of Stress Analysis

Note: The Cylinder to cover flange is a metal to metal joint sealed by an O-ring. For solid metal to metal joints of this class [with joint flexibility
constant C=0] the cylinder gas force acting upon the bolt or stud will cause a highest dynamic tensile load on each stud that is equal to the
maximum gas pressure in Cylinder x Flange internal area, divided by number of studs. This Dynamic load can be eliminated only if studs maintain
their tensile preload above what is called a threshold level of preload in each stud.

First stage cylinder suction pressure: 20.5 Bar= 0.21 Kg-mm**2. First stage discharge pressure= 39.8 Bar = 0.41 Kg-mm**2
Cylinder Bore Diameter: 600 mm per data sheet. Studs size: 24 studs x M27 size meaning 27 mm thread major diameter
Thread Root minor diameter for M27 stud course thread from tables= 23.32 mm. This will be used for stud stress and strength calculations.
Stud X-section area for stress calculations= 3.14 x [23.32] **2/4= 426.9 mm**2. Minimum SNB7 Material Tensile Yield strength= 53.0 Kg/mm**2.
Total surface area of gas acting on flange = 3.14 x [600 mm] **2/4= 282,600 mm**2.
Maximum Applied Gas Force per revolution on each Stud = Discharge pressure x Total cover area/Number of Studs
= 0.41 x 282,600/24= 4780.1 Kg per stud.
Maximum Stress on each stud from gas loading = Gas Force per stud /stud thread root x-sectional area= 4780.1/426.9= 11.2 Kg/mm**2
This tensile loading is the Threshold of Fatigue: If stud preload tension drops below 11.2 Kg/mm**2 then fatigue will be transferred to the studs.
Maximum Alternating Force per stud= [Discharge Pressure-Suction Pressure] x Total area/number of studs= [0.41-0.21] x 282,600/24= 2355.0
Kg per stud
Maximum Alternating stress in each stud= Max Alt Force per Stud/Thread X-sectional area= 2355/426.9= 5.52 Kg/mm**2 Dynamic Loading
The Stud Preload if Joint is designed well: Should be torqued to at least 50% of proof load: 0.50 x 53 Kg/mm**2= 26.5 Kg/mm**2 Static Loading
This calculation is neglecting bending moment arising from flange bending from internal pressure which adds additional stress to the studs,
however in this case due to thickness of valve cover its stiffness greatly reduces bending. The calculations also assume that all studs are stressed
equally by flange gas forces, however this is not technically correct as studs are exposed to alternating gas forces based upon their individual
preload tension. This becomes an unknown. It can be said that the studs will experience almost equal loading if all studs actual tension after
torqueing is within a range of 10% preload variation maximum. However, with OEM standard method of torqueing and bolted joint design, the
stud tensile preload will vary by more than 30% due to friction in threads, friction under nuts, and loss of initial tension during operation from
very low preload or stud stretching using 375 N-M. This scatter of preload values is unacceptable for critical joints.

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Technical Review: Reciprocating Hydrogen Make-Up Compressor First
Stage Cylinder Head Cover Flange Stud Failures
By Abdulrahman Alkhowaiter, Machinery Consultant, August 2021

This alternating stress of 5.52 Kg/mm**2 equals 7849.1 Psi stress per unit area on each stud in inches-pound system. By dividing stress with the
minimum tensile strength of stud: 5.52/ 53.0 kg/mm**2= 10.4% of Yield strength. This stress is not considered excessive so the diameter of M27
stud is having an acceptable safety factor if preloaded per proper mechanical design of joint. However failure by fatigue stress cycling on stud
will occur if the stud’s preload tension drops below the 11.2 Kg/mm**s threshold limit. This is what caused this dangerous failure event to occur.
According to plant personnel, the C-4002B First Stage Cylinder stud nuts were last torqued by compressor technicians in 2019. This removes
human error as a cause of failure as factory technicians are professional. Next, all process trends taken show no deviation from normal suction
and discharge pressure exceeding Data sheet conditions, and no evidence of any Liquid entry or buildup in KO drums as gas is extremely dry.

Joint Design Conclusion & Solutions:

1. The First stage cylinder cover flange studs failed from fatigue based upon x-section of studs. Engineering analysis of the M27 Stud Diameter
and Number of studs [24] shows that it is a proper design from a geometric point of view for operational design loading.
2. The OEM Stud material strength for this purpose should be in range of minimum 86,000 to 110,000 psi Tensile Yield meaning 60.50 to 77.30
Kg/mm**2. The gas compressor OEM has reported the studs to be SNB7 which is a JIS standard Alloy see table below. Its Yield strength can
vary from 520 MPA to 725 MPA which is 53.0 Kg/mm**2 to 74 Kg/mm**2. This equals 75,500 psi to 105,000 psi. This range is too wide as
the lower end of tensile yield range is considered a weaker material not suitable for the required service in terms of fatigue strength. The
Studs and Nuts should be complying with M8.8 or M9.8 rating or American Material Stud rating of ASTM A193 B-7.
3. The first defined cause of stud fatigue failure is the reduced strength rating studs used by manufacturer.
4. The second cause of this fatigue failure is the low Preload value utilized by manufacturer, 375 N-M of torque. This preload leads to fatigue
loading of the studs as the stud easily loses preload, while high preload tension studs have a stronger stretch and resist loss of preload
tension. They elected to use this low preload because their A216 Grade WCA Cast Steel Cylinder Threads material can have a tensile strength
as low as 21.1 kg/mm**2 which is 30,000 psi. Improved Design of Studs: By utilizing Lubricated Grade 8.8 M27 threads these apply 650 N-
M torque using torque wrench and lubricated threads. This rating is 50% of stud proof load if M8.8 rated strength. The preload depends
upon actual grade of stud installed showing importance of proper strength rating of studs and bolts. However, this will exceed thread strength
in Cylinder so standard torqueing not possible.
5. Cylinder Thread Depth and Stud Engagement: It was found that the Cylinder threads are 50 mm deep. However per manufacturer STD studs
which have a limited thread area see attached Fig-7 the actual thread length engaged by studs is only 29.0 mm.
6. High Tensile preloading cannot be utilized: Because Cylinder female threads are only 29.0 mm engaged and the Cylinder material thread
tensile yield strength can be as low as 30,000 psi meaning 21.1 Kg/mm**2. However it is possible to use a slightly higher limit since the
Thread Ultimate Tensile strength is 60,000 psi meaning 42.2 Kg/mm**2. Install new Studs with 41.0 mm engagement minimum.
7. Modification of Stud Preload to accommodate Weaker Female Threads: Since cylinder has weaker threads, the designer is forced to use
reduced preload stress so a reduction to a preload of 40% of stud strength is needed meaning 0.40 x 60.5 Kg/mm**2= 24.2Kg/mm**2. That
is equal to a thread stress of 34,400 psi. This equals a preload torque of 520 N-M lubricated. Only use this torque rating in the future.
8. The third cause of failure is the Joint with Nuts tightened directly on Head flange without washers. This causes high friction of nut on flange
steel surface which is not hardened. Result is a loss of initial stud torque-preload due to high friction so stud final tension preload is lowered.
Correct Design: Should have hardened steel, thick washers under all Cylinder cover nuts. Washer diameter is 60 mm minimum.
9. The fourth cause of failure is OEM method using dry torqued nut threads and also no lubricant under the nut face. This causes a high loss of
initial nut torque and loss of stud preload tension. Correct design: All Nuts shall have antiseize paste installed under the nut facing stud, and
inside threads before torqueing.
10. The First stage Cylinder Casting threads depth are complying with API-618 Fifth Edition para.6.8.1.6, see below extract. The Cylinder tapped
threads depth is of correct mechanical joint design meaning a minimum of 1.5 x Stud Diameter= 1.5 x 27.0= 40.5 mm depth. However actual
OEM studs are only engaging 29.0 mm when fully installed tightly into the holes which is not in compliance to API-618; should be engaged
by 40.5 mm. This design error reduces ability to utilize higher preload torque on studs and drives the joint closer to fatigue failures as higher
preload cannot be applied thus introducing fatigue forces in studs. Install new Studs with 41.0 mm engagement minimum.
11. Studs must be manufactured with rolled threads in this high stress machinery, not machined and cut threads. Machined threads have high
stress risers and are improper design for this service.
12. Additional Torqueing Procedure Required: Once all studs have been torqued fully with torque wrench; then wait 24 Hours and repeat
torqueing of all nuts again as the bolted joints always have settlement or imbedment causing some loss of preload. This second tightening
will bring all studs to within 10% preload tension variance which is the desired max variation.
13. Bolts-Studs Joint Reliability in service: Excessive opening and closing of flanged Joints due to Excessive PMs will lead to fatigue failures of
joint members. This means that such machinery flanges should not be opened frequently. For Modern condition monitored reciprocating
compressors, apply full mechanical PM at 16,000 Hrs. It’s important to perform a complete machine Bolt-Studs tightening at 8500 Hours.
14. Bolted Joint Design Upgrade option: Standard Hex nuts can be replaced with special nuts called Flexnuts which are designed to maintain
joint preload and produce higher fatigue resistance of the joint. See drawing below.
15. Remaining Stages Cylinder Head Covers: The above conclusions must also be applied by compressor manufacturer Cylinders 1-4 in terms of
stud strength, stud material, nut strength, preloading torque, washer requirement, and lubrication during torqueing. Each cylinder has
different calculations of preload torque. All the Cylinders Studs may have been exposed to fatigue.

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Technical Review: Reciprocating Hydrogen Make-Up Compressor First
Stage Cylinder Head Cover Flange Stud Failures
By Abdulrahman Alkhowaiter August 2021

Fig-6: Failed Stud showing complete length and actual engaged Stud to Cylinder Female Thread of 29.0 mm. Field Measurements:
The stud bolt total length is 195 mm. The stud bolt threaded length is 174 mm. There is a machined, 21 mm unthreaded length at end.
Cylinder female depth thread is: 50 mm. The stud bolt mating thread engagement inside the cylinder is only 29.0 mm and 21 mm length of the
stud bolt is free space without thread. This is incorrect design not meeting API-618 1.5 x Stud Diameter Engagement rule meaning 40.5 mm.

1st Stage Original Design M27 Stud Joint Improved Design M27 Stud Joint

Stud Material Minimum Strength 53.0 Kg/mm**2 Stud Material Minimum Strength 60.5 Kg/mm**2

Stud Nut Preload Torque is 375 N-M Unlubricated Stud Nut Preload Torque is 520 N-M lubricated

Stud Thread Engagement in Cylinder: 29.0 MM Stud Thread Engagement in Cylinder: 41.0 MM

Nuts Tightened On Head Flange Without Washers Nuts Tightened With Washers On Head Flange

Studs Manufactured With Machined Threads Studs Manufactured With Rolled Threads

Fig-7: Comparison of OEM Joint Design with Improved Design Giving No less than 300% Improvement in Reliability against Fatigue Failure.

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Technical Review: Reciprocating Hydrogen Make-Up Compressor First
Stage Cylinder Head Cover Flange Stud Failures
By Abdulrahman Alkhowaiter, Machinery Consultant, August 2021

Fig-8: The Cylinder Minimum Tensile Yield Strength is 30,000 psi, meaning 21.1 Kg/mm**2. Cylinder Female Thread has this strength.

Fig-9: API-618 Fifth Edition Cylinder Design Data. It is requiring the female thread and stud to have engagement of 1.50 x Stud Diameter

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Technical Review: Reciprocating Hydrogen Make-Up Compressor First
Stage Cylinder Head Cover Flange Stud Failures
By Abdulrahman Alkhowaiter August 2021

Cylinder Cover Stud Alloy Grade SNB7

Chemical Composition, Standards and Properties
Grade : SNB7

Classification: Structural steel

Standards: JIS G 4107 : Alloy Steel Bolting Materials For High Temperature Service

Applications: High-Temperature Pressure Vessels Valve And Coupling Bolts

Chemical Composition % of Grade SNB7

C Si Mn P S Cr Mo

0.2 -
0.38 - 0.48 0.75 - 1 max 0.04 max 0.04 0.8 - 1.1 0.15 - 0.25
0.35
Mechanical Strength Properties of Grade SNB7

Yield point or Proof Charpy impact

Assortment Tensile strength Elongation Reduction of area
stress strength
- N/mm 2 N/mm 2 % % J/cm 2
520-725 690-860 16-18 50

Fig-10: Stud Alloy SNB7 Steel Material Strength Data Sheet

Fig-11: Flexnut by Nordloc. Combines Benefits of flanged Nut with Self-Compensating Deflection Design Giving High Fatigue resistance.

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Technical Review: Reciprocating Hydrogen Make-Up Compressor First
Stage Cylinder Head Cover Flange Stud Failures
By Abdulrahman Alkhowaiter, Machinery Consultant, August 2021

Fig-12: Stud Thread Major Diameter versus minor Diameter. Only Minor Diameter is used for Stress Calculations

Fig-13: Proper Design Flanged Bolted Joint: Notice Use of Heavy Duty Flanged Nuts Equivalent to Hardened Washers under Nuts

End of Report

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