Design Calculation

CLIENT : Date: 01-02-2020

REF. : Design Calculation of Spacer Spool as

per API
DESIGN BASIS

1- Reference Design Spec for Equipment is API Spec 6A, 20th edition and API Spec 16A, 3rd edition,
ASME B 16.47 and ASME Sec VIII Div 2.0 (Plus 2004 / 2005 / 2006 addenda).

2- API spec 6A is for Specification for Wellhead and Christmas Tree Equipment - Purchasing Guidelines
- Basic requirement of above specification is dimensional and functional interchangeability Thus Flange
dimensions has to be as per standard.

3- API spec 16A is for Specification of drill-through equipment used for drilling for oil and gas. It also
defines service conditions in terms of pressure, temperature & well bore fluids for which the equipment
will be designed

4 - Equipment specific Design Requirements for Flanged end connections - Refer Clause 5.3.1.1
of API Spec 16A - Reads as " Flanged end and outlet connections shall conform to the dimensional
requirements of API 6A "

5- Material Grade : AISI 4130, 75 ksi (Min Yield strength= 75ksi)

Material Class : DD
DD - Sour Service (Min Material requirement is Carbon or low alloy steel)
Temp Class T : 0“ F to 180“ F

Material Class : DD - Sour Service (*Material requirement is Carbon or low alloy steel),
*As defined by NACE Standard MR0175 / ISO 15156

6- NACE Standard MR0175 / ISO 15156 : Above Standard is for Selection of Materials (cracking-
resistant materials) for use in H2S-containing Environments in oil and gas production

7- Product Specification level : PSL : 3

PSL-1: Equipment meets the minimum requirements of API Spec 6A, 20th edition for Design,
Specification, Qualification, Process inspection etc.

PSL-2: Meets all requirements of PSL-1 and contains additional testing requirement, along with different
ceiling limits of mechanical properties, and require Charpy impact testing conditions.

PSL-3: Meets all requirements of PSL-2 and contains additional requirements like Restricts the tolerance
of material chemistry, more stringent testing requirements like CVN testing for all service temperature,
wet magnetic particle inspection of all accessible surfaces, Hydrostatic test time extended etc. - are not
part of Design calculation

8 - Vendor drawing has Flange and Ring Gasket Dimensions as per API Spec 6A, 20th edition as shown
in Calculation Table - Thus Calculation Part is only to re- verify Flange/Pipe thickness, and Bolt sizes

9- Corrosion allowance is not considered in design calculation Also Max Design Pressure is assumed
equal to Flange class i.e. for class 5K, Design Pressure considered as 5000psi and for class 10K, Design
Pressure considered as 10,000psi
- As it is Spacer Spool, in actual, 10K Flange side will be subjected to Max 5K Pressure only

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 Design Calculation

10- Bolting Material: As per ASTM A193 Grade B7 Bolts

- Min UTI 125 KSI & Min Yield 105 KSI for A193 Bolts

11- Reference Drawings Provided by Vendor for Spacer Spool, 2 1/16” 5K RX24 x 2 1/16” 10K BX 152

A - Design Calculation for Spacer Spool

Given
Spacer Spool (API Spec 16A) ) : 2 1/16” 5K RX24 x 2 1/16” 10K BX 152
Material Grade : AISI 4130, 75 ksi,
Temperature Class : T (0 to 180 deg F)

Sketch
- Refer sketch : For Details, - Refer Vendor Drawing of Spacer Spool

Design Report:
Spacer Spool has one end Flange 5000 psi and other end Flange is 10000 psi

Spool Dimensions are as shown in table below

All dimensions confirm to API Spec 6A 20th edition
SN. DESCRIPTION Abb Flange Class- Flange Class-
5KRating 10KRating
1 Flange Design Pressure – psi P 5000 10000
2 Flange size -- 2 1/16" 2 1/16"
3 Flange I/D d 2.062" 2.062"
4 Flange O/D -- 8.5" 7.875"
5 Flange Thickness – Total H 1.812" 1.735"
6 Bolt Circle Diameter C 6.50" 6.25"
7 No of bolt Holes -- 8 8
8 Bolt Hole Size -- 1.0" 0.875"
9 Bolt Size -- 7/8"- UN-9 3/4"- UN-10
Stress Area in mm2 298 216
10 R F Dia -- Flat Face 4.375"
11 Hub O/D D 4.125" 3.94"
13 Corner Radius - Hub & Flange -- 0. 125" 0. 375"
14 Seal ring No. -- RX24 BX152

Seal Ring Gasket Properties

SN. DESCRIPTION Abb. Flange Class- Flange Class-

5KRating 10KRating
1 Seal ring No. -- RX24 BX152
2 Seal Ring -Gasket- width - W A 0.469" 0.403"
3 Seal Ring Gasket - Height H 1" 0.403"
4 Pitch Dia. Of Ring Gasket P/G 3.75" 2.931"
5 O/D of Ring Gasket OD 4.172" 3.334"
6 Gasket Factor m 6.5 6.5
7 Min. Design Seating Stress Y 26,000 psi 26,000 psi
8 Effective Gasket Seating Width b 0.0586" 0.0504"
9 Seal Ring - MOC -- SS/ Nickel base alloy SS/ Nickel base alloy

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11 Seal ring Sketch- For Ref. only - --

Ref sketch from Flexitallic Ring
Gasket Catalogue

DESIGN CALCULATIONS
As per 2015 ASME Section VIII, Div-1

Operating Conditions

Condition one (1) requires a minimum load be determined in accordance with the following equation:
This equation states the minimum required bolt load for operating conditions is the sum of the
hydrostatic end force, plus a residual gasket load on the contact area of the gasket times a factor times
internal pressure.

Condition - 1
Operating Bolt Load:
Wm1 = Hydrostatic end Load (H) + Contact Load on Gasket surfaces (Hp)
=> Wm1 = π /4 x G² x P + 2 x b x π x G x m x P
Where
G = Diameter of location of gasket load reaction = Seal ring Pitch Diameter
G = 3.75" for 5ksi Flange & = 2.931" for 10ksi Flange
P = Design Pressure in psi = 5000 for Class 5ksi Flange and 10000 for Class 10ksi Flange
b = Effective sealing width in Inches
For Ring type Gasket,
Gasket width = W = 0.469" (for RX24- 5ksi) & W= 0.403" (for BX152- 10ksi)
Then Basic Gasket Seating Width, bo = W/8, If bo < 1/4" Then b=bo
As 'bo' = 0.469/8 = 0.0586" < 1/4" therefore b=bo= 0.0586" - For 5ksi Flange,
and 'bo' = 0.403/8 = 0.0504" < 1/4" therefore b=bo= 0.0504" - For 10ksi Flange

m = Gasket Factor = 6.5 and y = 26000 psi for Ring Joint gasket of SS/ Nickel base alloy material
Therefore:
Wm1 = π /4 x G² x P + 2 x b x π x G x m x P
= π /4 x (3.75)² x 5000 + 2 x 0.05862 x π x 3.75x 6.5 x 5000
= 55,223 + 44,893 = 100,116 - lbs for 5ksi Flange

Wm1 = π /4 x (2.931)² x 10,000 + 2 x 0.0504 x π x 2.931x 6.5 x 10,000

= 67,472 + 60,330 = 127,802 - lbs for 10ksi Flange

Gasket Seating Bolt Load : Wm2

Condition two (2) requires a minimum bolt load (Wm2) to be determined to seat the gasket regardless of
internal pressure as per formula:

Wm2 = π x b x G x y
Where 'y' is defined as the minimum seating stress in psi = 26,000 psi

Therefore:
Wm2 = π x 0.0586 x 3.75 x 26000
= 17,950 - lbs for 5ksi Flange

Wm2 = π x 0.0504 x 2.931 x 26000

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 Design Calculation

= 12,066 - lbs for 10ksi Flange

Higher of Wm1 and Wm2 to be considered for bolt load calculations

Bolt size Calculations;

For 5 ksi Flange :

No of bolt 8, bolt size 7/8" - UN-9, Tensile stress area of bolt = 0.462 Sq. inch
Therefore Max Stress in Bolt = Wm1/(8 x 0.462)
= 100,113 /(8 x 0.462) = 27,086 psi

For 10 ksi Flange :

No of bolt 8, bolt size 3/4"- UN-10, Tensile stress area of bolt = 0.335 Sq. inch
Therefore Max Stress in Bolt = Wm1/(8 x 0.335)
= 127,802 /(8 x 0.335) = 47,687 psi

Bolt Material is A193 Grade B7 Bolts with Min Yield stress = 105ksi

As per API Spec 16A 3rd Edition:

Bolt tensile stress, based on the minimum cross sectional area of the bolt or stud, shall not exceed the
following limits
𝑆𝑎 =0.83 𝑆𝑦 where Sy is Bolting Material Minimum Yield strength
Therefore 𝑆𝑎 =0.83 x 105ksi = 87,150 psi
Thus Tensile stress in Bolting are safe for both type of flange.
Additionally Induced stress for 10K Flange are calculated at Flange rating however in actual Spacer
Spool piece will be never subjected pressure for higher size Flange rating Thus Bolts stress for 10K
Flange will be much less, as Max operating can be 5000 PSI only

Bolt Spacing Calculations

As per 2015 ASME Section VIII, Div-1, Maximum Circumferential Spacing between Bolts Bs (max.)
= 2a + 6t/(m + 0.5)
Where
a= Nominal Bolt dia = 7/8" for 5ksi Flange and 3/4" for 10ksi Flange
t = Flange Thickness = 1.81" for 5ksi Flange and 1.74" for 10ksi Flange
m = 6.5 ( m- Gasket Factor)

therefore Bolt spacing Bs (Max) should be =

2 x 0.875 + 6 x 1.81 /(6.5+0.5) = 3.30" for 5 ksi Flange and
2 x 0.75 + 6 x 1.74/ (6.5+0.5) = 2.99" for 10 ksi Flange
Actual Bolt spacing Provided
= Sin (180/n) x BCD where n = 8 nos, BCD = 6.5" for 5ksi Flange and 6.25" for 10ksi Flange
= 2.49" for 5ksi Flange and 2.39" for 10ksi
Thus actual Bolt spacing is less than max. Permissible Bolt Spacing - O. K.

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 Design Calculation

Flange thickness Calculations in Detail

SN Description Notation Unit 5k flange 10k flange

Loads
1 Internal Pressure P psi 5000 *10000
Flange Allow. at Amb. Temp
2 =1/2 of Yield 75ksi =37500 Sfs psi 37500 37500
Flange Allow. at Design Temp
3 =1/2 of Yield 75ksi =37500 Sfd psi 37500 37500
Bolt Allow. at Amb. Temp
4 =1/2 of Yield 105ksi =52500 Sa psi 52500 52500
Bolt Allow. at Design Temp
5 =1/2 of Yield 105ksi =52500 Sb psi 52500 52500
6 Gasket Factor m psi 6.5 6.5
7 Gasket Factor y psi 26000 26000
Dimensions
8 Flange OD A inch 8.50 7.88
9 Flange ID B inch 2.06 2.06
10 Bolt Circle Diameter C inch 6.50 6.25
11 Hub Thickness at Small end g0 inch 1.03 0.94
12 Hub Thickness at back of flange g1 inch 1.03 0.94
13 Hub Length h inch 2.00 2.50
14 Flange Thickness t inch 1.81 1.74
16 Nominal Bolt Diameter a inch 7/8 3/4
17 Number of Bolts n 8 8
18 Area of Bolt at Thread Ac inch 2 0.462 0.335
19 Gasket OD inch 4.172 3.334
20 Gasket ID inch 3.234 2.528
Calculations

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21 Width of Gasket N inch 0.469 0.403

22 Basic gasket seating width bo inch 0.059 0.050
23 Effective Gasket width b inch 0.059 0.050
24 Location of Gasket Load G inch 3.750 2.931
25 Equivalent Pressure Peq psi 0.00 0.00
26 Total Pressure P psi 5000 10000
27 Total Hydrostatic End Force H lbs 55195 67435
SN Description Notation Unit 5k flange 10k flange
28 Total Compression Load Hp lbs 44883 60299
29 Bolt load for Operating Wm1 lbs 100078 127734
30 Bolt load for Seating Wm2 lbs 17944 12054
31 Area of Bolt for Operating Am1 inch 2 1.906 2.433
32 Area of Bolt for Seating Am2 inch 2 0.342 0.230
33 Required Area of Bolt Am inch 2 1.906 2.433
34 Bolt Stress % in Operating 51.59% 90.84%
35 Bolt Stress % in Seating 9.25% 8.57%
36 Is Bolt area Adequate YES YES

37 Flange Design Bolt Load Oper W1 lbs 100078 127734

Flange Design Bolt Load Seat
38 = Sa * ( Am + Ab ) / 2 W2 lbs 147038 134175
39 Radial Distance = ((C-B)/2)-g1 R inch 1.189 1.156
40 Moment Arm Hd = R + 0.5g1 hD inch 1.705 1.626
41 Moment Arm hT = (R+g1+hg)/2 hT inch 1.798 1.877
42 Moment Arm hG = (C-G)/2 hG inch 1.375 1.660
Hydrostatic End Force HD
43 HD lbs 16656 33312
= 0.785*(B^2)*P
44 Difference HT = H-HD HT lbs 38539 34124
45 Gasket Load HG = W1-H HG lbs 44883 60299
46 Moment MD = hD*HD MD inch-lbs 28389 54145
47 Moment MT = hT*HT MT inch-lbs 69271 64057
48 Moment MG = hG*HG MG inch-lbs 61712 100062
Total Operating Flange
Moo inch-lbs 159372 218263
49 Moment = MD+MT+MG
Total Seating Flange Moment
Mos inch-lbs 202170 222655
50 = W2*(C-G)/2
Calculate Stresses
51 Operating Longitudinal Hub Stress SHO psi 20717 34703
52 Operating Radial Flange Stress SRO psi 16785 25490
53 Operating Tangential Flange Stress STO psi 14339 23667
54 Seating Longitudinal Hub Stress SHS psi 26280 35401
55 Seating Radial Flange Stress SRS psi 21292 26003
56 Seating Tangential Flange Stress STS psi 18190 24143
PASS PASS
Note:
1- Minimum Yield stress of Flange Material is 75ksi, Thus Induced stress in both type of Flanges are safe

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 Design Calculation

2- * 10K Flange calculated for 10,000 psi Design Pressure However it can subject to Max 5000 psi only
as other end Flange is for 5K rating. -- Hence all stress shown above for 10K will be almost half of the
calculated stress.

Design Sketch of Spacer for Ref

Spacer Spool : 2 1/16” 5K RX24 x 2 1/16” 10K BX 152

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 Design Calculation

Additional Calculations for Flange Hub Thickness

Hub Thickness calculation for internal pressure as per 2015 ASME Section VIII, Div-1
Flange Hub can be considered as thick pipe subjected to internal pressure
Note:
As It is Spacer spool , it will subject to max 5000 PSI only, Thus Hub thickness and induced stress to be
calculated for 5000 psi Pressure only.

Where
t = Thickness of Hub required
P = Pressure = 5000 psi
R = Internal Radius = 2.06"/2 = 1.03"
t = 5000 x 1.03 S = Allowable stress value of Material
37500 - 0.6x 5000 E=1
= 0.150 " Assume 1/2 of Yield = 1/2 x 75000 = 37500 psi
Actual thickness of Hub Corrosion Allowance - Nil
= (3.94 - 2.06)/2
= 0.94"

Additionally, Stress distribution in Thick Cylinder using Lame's Equation - As per Engineering text books
for Tangential stress at any radius x = σt = [p*Ri²/(Ro²-Ri²)]*[1+(Ro²/x²)]

Description 10ksi Flange

Hub ID d 2.06"
Hub OD D 3.94"
Hub Thickness : t t 0.94"
Inner radius of Cylinder = Hub ID/2 = d/2 Ri 1.03"
Outer radius of Cylinder = Hub OD/2 = D/2 Ro 1.97"
Internal Pressure P 5000 psi
Tangential stress at Inner Surface when x=Ri --
8762 psi
σt-Inner = p*(Ro^2+Ri^2) /(Ro^2-Ri^2)
σt- Middle = [p*Ri^2/(Ro^2-Ri^2)]*[1+(Ro^2/x^2)] -- 5126 psi
σt- Outer = 2*p*Ri^2 /(Ro^2-Ri^2) -- 3762 psi

All stress are well in the limit for Flange Material AISI4130 with Min Yield stress 75ksi

Design Report:

DSA Spacer is connecting part between two Flanges, hence No specific design calculation
applicable Only it should meet following requirements.

1- BCD, Tapped Hole sizes, Flange ID, max Flange OD and Ring Gasket Groove Dimensions
to match with matching Flange also All dimensions should be as per API Spec. 6A, 20th edition
- All Dimensions meets the requirement.

2- As per API spec 16A, 3rd edition Minimum depth of full threads in the holes shall be equal to
the diameter of Stud - For 7/8" Tap size, Tap depth is 1.10" . Thus it satisfy the condition

3- Groove dimensions for Seal ring Gasket BX152, are as per API Spec 6A / ISO10423, Table
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