Flange Leakage checking in Caesar II using ASME Section VIII method

My last two articles on flange leakage explains the basic theory behind flange leakage checking and methods for performing flange leakage checking using pressure equivalent method. In this article I will explain the steps taken to perform flange leakage check using Caesar II by ASME Sec VIII method. Normally this method is performed when the analysis in pressure equivalent method shows failure in Caesar II. Pressure equivalent method being too conservative does not provide us the actual realistic results. Hence this method is widely accepted where pressure equivalent method shows a failure. The steps involved are mentioned below:
  • After performing static analysis click the “Analysis” and then click “Flanges” in CAESAR II as shown below.
  • Provide a file name and select the proper Flange Type in the section as mentioned in the PMS. Input the flange parameters as shown below:
  • Press the key “Ctrl+F” to select the concerning Size and Rating. Few data will automatically filled from Caesar II database. However it is good practise to confirm the data from governing code.
  • Flange Class is the flange pressure rating and is required for checking P-T Rating of Equivalent Pressure.
  • Flange Grade: Select Material Group No. as per ASME B 16.5 Table 1A list of material specification. Following table can be used as reference:
  • Refer to the applicable flange code ASME 16.5 or ASME B 16.47 and update automatically filled flange data. Take special care while inputing for ‘Small End Hub Thickness’& ‘Large End Hub Thickness’. ‘Small End Hub Thickness ’  must be equal to the Pipe Thickness. Large End Hub Thickness must be equal to (X-B) where X is Hub Diameter and B Flange ID.
  • Enter hub Length h=(Y-tf) where Y is length through Hub and tf is flange thickness.
  • Now it is the turn to enter the Bolts and gasket parameters. Take parameters from ASME B 16.20 or ASME B 16.21 as shown below:
  • Check Bolt Circle Diameter, Number of Bolts and Bolt Diameter, suggested by CAESAR II in reference with ASME B 16.47, 16.5.
  • Correctly input for Gasket information in conjunction with ASME B 16.20 or 16.21 as applicable.

For Effective Gasket Modulus, press Shift+? Key and then follow “High End” in Help statement. Leak Pressure Ratio m, Gasket Seating Stress y shall be in accordance with ASME SECTION VIII Div.1. Values for Caesar II help can be taken by pressing Shift+?.

  • For Nubbin Width in the right side, Leave blank for Welding Neck Type and input Ring joint width as per the ring no. as described on ASME B 16.20 Table 3 TYPE R RING GASKET DIMENSIONS AND TOLERANCES for ring type joint.
  • Facing Sketch/ Facing Column can be inputted as follows mentioned below:
  • Now input the material data as shown below:
  • Select the material of Flange and bolt, and Input design temperature.
  • Flange Allowable & Bolt Allowable at design and ambient temp can be taken from CAESAR II database for particular flange and bolt material.

Flange Modulus of Elasticity shall be taken from table C-6 of ASME B-31.3.which is given in millions of psi convert it to consistent unit

  • Use 1.0 for Flange Allowable Stress Multiplier and 2.0 for Bolt Allowable Stress Multiplier. Use project specific data if available.
  • Now Input Design Pressure, Axial Force, Bending Moment from Static analysis of the Caesar file as shown below:
  • Now run the analysis to study the output results. Normally If safety Factor is less than one then joint failure is predicted and in output this is shown by a * mark.
  • If result shows failure then try to reduce the bending moment or axial force and reanalyse. If that is not possible check if the flange rating can be increased.
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Anup Kumar Dey

I am a Mechanical Engineer turned into a Piping Engineer. Currently, I work in a reputed MNC as a Senior Piping Stress Engineer. I am very much passionate about blogging and always tried to do unique things. This website is my first venture into the world of blogging with the aim of connecting with other piping engineers around the world.

9 thoughts on “Flange Leakage checking in Caesar II using ASME Section VIII method

  1. I am performing flange leakage analysis check for various flanges on a project, and most of them failed the check. These are above grade flanges in a gas pipeline facility (main line valves, pig launchers). I am not considering external pressures or moments. Can you help with troubleshooting? Thank you, Ada.

    1. Uncompressed gasket thickness is available in ASME B 16.20. Normally it is 4.45 mm. Otherwise the same can be specified in piping material specification.

  2. I have to perform flange leakage analysis of flange having following specifications:

    In CAESAR software data base API flange option is not available but only ASME and EN codes are there. Now, to perform the analysis for my above mentioned flange what procedure I have to follow in CAESAR.

    Your urgent response will be highly appreciated.


  3. Well i get the axial force (i.e in the direction of pipe)eg. be it in X direction, how do i get the bending moment. since it is in two directions i.e in Y and Z . Should i take the higher of the two values or should i take its square root sum ?

  4. Hi,
    really interesting article; often i have to perform leakage test in caesar2 environment and often I find more problems at seating than in operative conditions. The main reason is the gasket seating “y” because somtimes client ask to insert the seating load applied on tie rods acc. to PCC1 (so resulting in really higher values of “y” than the values listed in the ASME VIII div1 App.2) and to apply the verification in ASME VIII Div1 App.2 resulting in overstress in both bolt and flange itself…have you ever found a problem like this?


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