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Bolted Steel Tanks | Design and Construction

A Bolted tank is one of the atmospheric storage tanks that also play an important role as an alternative to the Welded Tank. These tanks are made from factory-manufactured section staves (known as a Shell-Course in Welded Tank) that have been manufactured in a quality-controlled factory setting. Bolted steel tanks have been in use for more than fifty years. So, the design and construction of bolted tanks are already tried and proven. They provide a long-term, cost-effective solution for a wide variety of uses.

Under certain conditions, a bolted tank is more often selected

  • for conditions in which there is no provision to allow hot-work in order to repair/replace an existing tank or built a new one, and
  • when there is a concern about the limitations of the working area from the tank user.   

Applications of Bolted Tanks

These tanks are commonly found in industrial, commercial, residential applications ranging in size from a few 100 bbls to 10,000 bbls. The most common applications of bolted tanks are listed below:

  • Water Sector: Storage of Drinking or Potable Water, Rural Water Districts, Subdivision/Private Water Systems, Water Storage at Municipality, Fire Protection Systems, Waste Water, Finish Water, Process Water, Disinfection, Filtration, and Sludge Storage.
  • Food Industry: Salt factories, Flour & Sugar industries, Meals: Soybean, Bone, Fish, Corn, Meat, Blood, Dried Distillers Grain, Starch, Milk Solids, etc
  • Mineral Storage: Talc, Lime, Bentonite, Calcium Carbonate, Alumina, Gypsum, Silica, Coal, Phosphates, etc
  • Petroleum Products: Drilling Fluids, Crude Oil Storage, Mud, Fuel Oil, etc
  • Chemical Storage: Carbon Black, Cement, Activated Carbon, Sodium Nitrate, Fly Ash, Urea Pellets, Sodium Carbonate, Glass, Soda Ash, Potassium Carbonate, etc
  • Storage of Bio-Fuels: Caustics, Glycerin, Syrup, Bulk Bio-Diesel, Methanol, Yeast Tank, Raw Feedstock Oils, etc.
  • Power generation Industry: Treatment Bins & Silos, Coal Storage, Desulphurization Systems, Fly Ash Storage, etc

In most sectors of the oil production industry, Bolted Tank can also be used to store crude petroleum and other liquids with or without internal piping connections.

In this article, we will study the design and installation of Bolted Tanks that was carried out by the Author during on-site work at South Sumatera, Indonesia.

Bolted Tank at Installation Stage
Fig. 1: A typical Bolted Tank at Installation Stage

Bolted Tank Design Standard

The API Specification 12B by American Petroleum Institute covers the material, design, fabrication, and testing requirements for vertical, cylindrical, aboveground, closed, and open-top bolted tanks in various standard sizes and capacities.

Generally, these tanks are made for tanks that have internal design pressure approximately atmospheric of:

  1. 3 oz/in.2 for tanks with a diameter of 15 ft, 45/8 in. and less;
  2. 2 oz/in.2 for tanks with a diameter of 21 ft, 61/2 in. and 29 ft, 85/8 in.;
  3. 1 oz/in.2 for tanks with a diameter of 38 ft, 75/8 in. and greater.

API Specification 12B Tanks are divided into several capacities based on bolted tank roof diameter as follows:

  1. Low Capacity Tanks – Bolted Tanks with a roof diameter under 29 ft, 85/8 in. (100-bbl, 200-bbl, 250-bbl, high 500-bbl, 750-bbl, low 500-bbl, high 1000-bbl, and 1500-bbl capacity) are self-supporting.
  2. Medium Capacity Tanks – Bolted tanks with a roof diameter of 29 ft, 85/8 in. (low 1000-bbl, 2000-bbl, and 3000-bbl capacity) that are furnished with a structural- or pole-type center support, including a rafter support ring.
  3. High Capacity Tanks -Bolted Tanks with a roof diameter greater than 29 ft, 85/8 in. (5000-bbl and 10,000-bbl capacity) that furnished with pole-type center support.

Advantages of Bolted Tanks

Bolted Tanks offer various advantages as mentioned below:

Precision in Fabrication

In some quality-controlled factories, bolted tanks are manufactured from superior raw material in accordance with API Specification 12B including cutting, punch press, rolling, bending-into-shape, and applied superior powder coating on the stave surface for both internal or external side.

Ease of Assembly

Unlike a large field-storage tank that assembles on-site through welding, with strict erection method, a lot of time of inspections, and coating application then the bolted tank can be installed in any situation and arrive at the job site as a ready-to-assemble tank. It makes the erection and construction period very short.

Another important thing that bolted tanks can be erected and bolted up to second rings manually by scaffolding because of its less-weight staves and appurtenances compared to a welded tank that usually uses cranes.

Durability Coating

Surface preparation (SSPC-SP10) and coating application can be applied in the factory-manufactured tanks in a good quality-controlled environment prior to transporting to the job site.

This is very different from large-filed welded tanks that are required to be painted or coated at the job site until the erection/installation is completed.

One of the best coatings used in API Specification 12B Tank is powder coating. These coatings are applied for both internal and external surfaces of each part from 8 to 10 mils of DFT.

Bolts of staves also coated by mechanically zinc-coated or hot-dip galvanized in manufacturing facility depends on client requirements.

Flexibility of Construction

Bolted tanks can also be built over a concrete ring wall (Fig.2A), Concrete Slab (Fig.2B), and Steel Retaining Ring Foundation (Fig.2C).

Bolted tank construction over various foundation
Fig. 2: Bolted tank construction over various foundation

Easy Maintenance of Bolted Tanks

Any damaged part caused by corrosion on panel/section of staves, nozzle neck, clean-out, and gaskets can easily be unbolted and replaced or repaired on the job site.

Bolted Tanks are subject to leaks but can be simply maintained and repaired. In case of any leakage at bolt connections during the hydro test, it is easier for an operator to detect leaks and then re-tightening the bolts using proper tools such as Torque Wrench.

Tank in Box? Yes

Since bolted tanks are shipped disassembled in sections, they are more compact to transport to the laydown area than the large shell-course of a field-welded tank, and reducing costs.

These staves and accessories usually are packed in banded pallets with ranging sizes and transported by container.

Disadvantages of Bolted Tanks

There are some disadvantages while choosing Bolted Tank as per API Specification 12B:

  1. Anchorage for overturning loads and
  2. Seismic design

They are outside of the scope of API Specification 12B Tanks. Therefore, engineering judgment shall be considered to refer to another storage tank code calculation such as Annex E of API Standard 650.

Bolted Tank Design

Basic Tank Configuration (Bolted Tank Parts)

Bolted Tank configuration depends on the capacity of each tank. Refer to Fig. 3 below explaining the parts of a bolted tank.

Bolted Tank Parts
Fig. 3: Bolted Tank Parts

Material of Construction of Bolted Tanks

Bolted Tanks are mostly made of steel that is why it is also known as bolted steel tanks. Typical materials used in bolted tank design are

  • Staves (Shell Sheets): ASTM A1011 Grade 40 (not less than 36,000 psi of SMYS)
  • Structural shapes: ASTM A36
  • Center column: ASTM A53 Grade A
  • Man-way & Cleanout: ASTM A1011 Grade 40
  • Piping: ASTM 106 Grade B
  • Flange: ASTM A105
  • Fitting: ASTM A234 WPB
  • Gasket: Buna Nitrile, Epichlorohydrin, and EPDM strip
  • Bolt/Nut: ASTM A307 Grade A / SAE Grade 5 / SAE Grade 2.

Size of Bolted Tanks

Bolted Tank designed per API Specification 12B shall conform to the sizes and dimensions below:

Bolted Tank Sizes
Fig. 4: Bolted Tank Sizes

Details of Bottom, Shells, and Roofs

Bolted tank Bottom, Shell and Roof Details
Fig. 5: Bolted tank Bottom, Shell and Roof Details

Bolted Tank Construction

In this section, we will briefly discuss the installation sequence for a typical Bolted Tank.

Step 1: Preparation of Bolted Tank Foundation

The first stage in bolted tank construction is to prepare the foundation. Civil team design the foundation based on soil investigation and construct as per design drawings.

Levelness of the foundation shall be check to provide an easy fitting bolted tank.

Foundation of Bolted tank
Fig. 6: Foundation of Bolted Tank

Step 2: Assemble the Bottom (Tank Floor)

In this step the following activities are performed

  • Spread the Impingement Fibreboard
  • Spread and assemble the Bottom Staves from the center of the tank
  • Rubber the Bottom with Strip Gasket until complete
Assembling the Bolted tank bottom
Fig. 7: Assembling the Bolted tank bottom

Step 3: Assemble the Staves and Rubbering with Strip Gasket

In this stage, the staves are assembled to give the tank shape. It is a good practice that the first stave to be installed on tank bottom is a stave fitted with a access man-way or clean-out.

Assembly of Bolted tank staves
Fig. 8: Assembly of Bolted tank staves

Each panel is bolted together using custom made rubber gaskets to prevent any leakage.

Using Rubber Gaskets in between panels of bolted tanks
Fig. 9: Using Rubber Gaskets in between panels of bolted tanks

Step 4: Positioning the Center of Column Base Sleeve

Internal columns shall be guided or supported to resist lateral loads (remain stable) even if the roof components are not specified to be designed for the seismic loads, including tanks that need not be designed for seismic ground motion.

Positioning the Center of Column Base Sleeve
Fig. 10: Positioning the Center of Column Base Sleeve

Step 5: Assemble and Positioning the Center Pole of Column Pipe

Assemble and Positioning the Center Pole of Column Pipe
Fig. 11: Assemble and Positioning the Center Pole of Column Pipe

Step 6: Assemble the Roof Deck

Assemble the Roof Deck
Fig. 12: Assemble the Roof Deck

Step 7: Installation of Internal Weir and Skimming Pipe

Installation of Internal Weir and Skimming Pipe
Fig. 13: Installation of Internal Weir and Skimming Pipe

Step 8: Complete Installation until Finish

Complete the Bolted Tank installation prior to installing the appurtenances of Bolted Tank as mentioned below.

Final Assembled Bolted Tank
Fig. 14: Final Assembled Bolted Tank Cap. 10,000 bbl

Fig. 15 shows the general arrangement drawing of the above Bolted Tank.

Sample of General Arrangement drawing of Bolted tank
Fig. 15: Sample of General Arrangement drawing of Bolted Tank (10,000 bbl)

Appurtenances of Bolted Tanks

The following accessories or associated items are relevant to bolted tank design and construction. Learn more according to the list below:

  • Vent / Breather Valve: to prevent overpressure and vacuum conditions by allowing atmospheric air to flow into the tank.
  • Pressure Vacuum Relief Valve: can act as Safeguard. However, if the tank contains hazardous material, these types of safeguards should only be considered as a last line of defense against the malfunction of other safeguards in the hierarchy. For more details, please refer to API 2000.
  • Roof Hatch / Gauge Hatch: which permits the cover to lift under abnormal internal pressure.
  • Flame Arrester (Vertical, In-line type): to prevent flames entry into the tank in the event of external fire
  • Cathodic Protection: Sacrificial anode c/w Portable Reference and Test Point to protect the tank from corrosion.
  • Internal Skimming Pipe: Optional, depending on Process Requirement. Install inside the tank; employed as oil & water separation.
  • Outside Tank Ladder & Spiral Stairway
  • Roof Walkways and Handrails
  • Access Man-way & Clean-out
  • Liquid Level Indicator: to monitoring the level of liquid inside of the tank, include LLL, Normal, and HLL.
  • Foam Chambers: to prevent flame by delivering foam to the surface of flammable.
  • Overflow Pipe: to prevent spillage by overfilling. It should be installed at the highest point of the tank shell at least as big as the largest inlet pipe, or larger if there is more than one inlet piping system.
  • Skimming Pipe Supports and U-bolt
  • Nozzles and Connection Pipes: include Flange, Nozzle Neck, and Bolting.
  • A nameplate (API Specification 12B Monogram).

Bolted Tank Manufacturers

There are a number of manufacturers who specialize in the manufacture of the bolted tanks made from the stave.

The following below are some of the suppliers widely known worldwide

  1. Superior Tank Co, Inc.
  2. CST Bolted Tanks
  3. American Tank Company, Inc.
  4. Tank Connection
  5. TARSCO-TF Warren Group
  6. National Storage Tank
  7. United Tank Services
  8. Center Enamel

Bolted Tanks vs Welded Tanks

Bolted Tank vs Welded Tank
Fig. 16: Bolted Tank vs Welded Tank

The major differences between bolted tanks and welded tanks are tabulated below:

Bolted TankWelded Tank
Bolted Tanks are designed as per API Specification 12B / AWWA D103Welded tanks are designed as per API Standard 650 / API Standard 620
Quick Installation is the main feature of bolted tanks.Welded tanks need more Installation time
Highly Flexibility in bolted tank installationInstallation of welded tanks is less flexible
Bolted tanks provide easy maintenance and RepairThe maintenance and repair work on welded tanks are comparatively Difficult
Bolted tanks provide a Cost Effective SolutionWelded tanks are relatively Costlier
Table: Bolted Tank vs Welded Tank

References and Further Studies

For more details about Storage Tanks, you may refer to these following articles:

https://whatispiping.com/brief-presentation-storage-tanks
https://whatispiping.com/storage-tank-failure-examples-causes-and-prevention
https://whatispiping.com/difference-between-api-650-and-api-620

Butterfly Valves: Uses, Types, Working, Advantages, Symbols

Butterfly valves belong to the quarter-turn rotational motion valves family and are used primarily to stop, regulate, or start the flow. The term “butterfly” in a butterfly valve is actually a disk that is connected to a rod. When this rod rotates the disk by 90° the butterfly valve opens or closes. Butterfly valves are popular in the industry because of their lightweight, fast operation, and low costs. These valves use handles, gears, or automatic actuators for operation as per the requirement.

Smaller-size butterfly valves usually have manual operation whereas larger devices are normally motorized. With high flow capacities, butterfly valves enable the use of smaller units that reduces weight, cost, and space requirement significantly. With only two wetted parts and a range of valve linings, butterfly valves isolate the body from the flowing media which eliminates the need for expensive exotic materials.

The smooth contoured, crevice-free disc produces lower torques, while the design of butterfly valves makes them easy to install, maintain, and service.

Butterfly Valve Uses

The use of Butterfly valves is broad and wide. Some typical applications of butterfly valves are in the water supply, wastewater treatment, slurry services, fire protection, air and gas supply, vacuum services, lubrication system, chemical and oil industries, fuel handling systems, power generation, compressed air and gas services, steam services, food processing, pharmaceutical, marine systems, and sanitary valve application. Basically, Butterfly Valves are suitable for use in

  • Constant Load Applications
  • Space-Restrictive Applications
  • Throttling Valves

Components of a Butterfly Valve

Components of a butterfly valve
Fig. 1: Components of a butterfly valve

There are four main components in a butterfly valve: body, disk, stem, and seat.

Valve body: the body of the Butterfly valves fits two pipe flanges, the most common body design is the lug and wafer type (Fig. 2).

Butterfly valve disk: The disk (disc) is the element that stops the flow. For improving flow, sealing, and operating torque, There are variations in disk design and orientation.

Valve Stem: The stem of the butterfly valve consists of a one-piece or two-piece shaft design. Stem design shall prevent galling potential between similar corrosion-resistant materials.

Butterfly valve Seat: To provide shutoff, the seat of a butterfly valve utilizes an interference fit between the disk edge and the seat. The seat may be bonded, pressed, or locked into the body.

The seat of the butterfly valve is an area that has various designs based on manufacturers. A single-piece flexible PTFE seat is a popular choice. The significance of the single-piece seat is that there are no O-rings or metallic springs to limit the temperature or corrosive conditions that the PTFE seat can be exposed to. With the application of the line pressure, the full cross-section of the seat is pressurized causing the seat to follow the natural deflections of the disc under pressure.

Advantages of Metal Seats in Butterfly Valves

Metal seats in the butterfly valves have various advantages and should incorporate the following:

  • good tightness
  • no jamming
  • smooth control
  • low torque
  • wide temperature range
  • low cavity relief
  • good corrosion resistance
Lug and Wafer Type Butterfly Valve
Fig. 2: Lug and Wafer Type Butterfly Valve

Functions of a Butterfly Valve

The main functions of a butterfly valve are

  • Flow regulation: Flow can be easily controlled or regulated simply by turning the valve wheel.Using a flow controller the process can be automated.
  • Flow Isolation
  • Prevention of Backflow: Butterfly valves can be used for backflow prevention in some situations.

Types of Butterfly Valves

Depending on disc closure design, connection design, and actuation method, Butterfly valves can be categorized into several types.

  • Based on the Disc Closure Design
    • Concentric Butterfly Valve
    • Eccentric Butterfly Valve
      • Single-Offset
      • Double Offset
      • Triple Offset
  • Based on the Piping Connection
    • Lug type
    • Wafer Type
    • Flanged Butterfly Valve
    • Butt-welded Butterfly Valves for high-pressure applications
  • Based on the Operation method
    • Manual Actuation
      • Lever Operated
      • Gear Operated
    • Automatic Actuation
      • Electric
      • Pneumatic
      • Hydraulic
  • Based on Seat Material
    • Soft Seated
    • Metal Seated

Concentric Butterfly Valve

The concentric butterfly valve is the most basic type of butterfly valve design. In this design, the valve stem passes through the centreline of the disc. This is also known as a zero-offset valve. Concentric butterfly valves are used for low-pressure services.

Eccentric Butterfly Valve

In an eccentric butterfly valve, the stem does not pass through the centerline of the disc. There are three types of offset valves.

  • A Single-offset valve is the butterfly valve where the stem is located right behind the centreline of the disc.
  • In a double-offset butterfly valve design, the stem is located behind the disc with an additional offset to one side.
  • For highly critical applications, a triple-offset butterfly valve is used. The third offset is in between the disc and seat contact axis. This design results in minimal seat contact thus very less wear and is highly efficient.
Single, Double and triple Offset Butterfly Valve Design
Fig. 3: Single, Double, and triple Offset Butterfly Valve Design

Lug Type Butterfly valve

The lug-style butterfly valve (Fig. 2) designs have threaded lugs outside the valve body. Using two sets of studs, the valve is connected with piping flanges. One end of the line can be disconnected without affecting the other side since each flange has its own bolts.

Wafer Type Butterfly Valve

A wafer-type butterfly valve is sandwiched between two pipe flanges and the flange bolts surround the valve body. This is the most economical butterfly valve. Long bolts are used to cover both flanges and the valve body. A wafer butterfly valve provides sealing against bi-directional pressure differences in the fluid flow. The wafer version of the butterfly valves is designed to protect against a tight seal and two-way pressure difference.

Wafer vs Lug Style Butterfly Valve

There are some distinct differences between the Wafer-type and Lug-type butterfly valves. The following paragraphs explain the same.

Lug-style butterfly valves use threaded tapped lugs to mount the valve to piping flanges using bolted connections. On the other hand, wafer-style butterfly valves don’t have attachment lugs. Usually, they have four holes to align with the connected piping. The valve is clamped in between two piping flanges.

A lug-style butterfly is suitable for end-of-line service but wafer-style butterfly valves can not be used for end-of-line services. In case there is a maintenance requirement on the line having water style butterfly valve, the entire line needs to be shut down.

Wafer-style butterfly valves are lighter and cheaper as compared to lug-style butterfly valves.

Butterfly Valve Sizing

The size of butterfly valves used for control purposes is not dictated by the pipe’s nominal diameter. The size is determined based on the operating characteristics to achieve correct control characteristics. To determine the size, the opening angle characteristics should be considered. Typically, some butterfly valves are designed with approximately equal percentage characteristics over an opening of 600.

The maximum working capacity is decided based on the body rating or the seat shut-off capability whichever is lower.

Butterfly Valve Advantages

Butterfly Valves provide many advantages as compared to other valve types.

  • Compact design; little space requirement.
  • Lightweight; easily supported by the piping system.
  • Less raw material and less costly.
  • Quick operation; less opening or closing time.
  • Easy to Install.
  • Simple operation due to low operation torque.
  • Available in very large sizes
  • Improved energy efficiency
  • Low-pressure drop and high-pressure recovery
  • Long valve life
  • Relatively inexpensive to build.
  • Less number parts; Hence, reduced maintenance.
  • Butterfly valves are suitable for control purposes with linear flow characteristics between 300 and 700 openings.
  • Butterfly valves offer excellent rangeability from 30:1 to 100:1.

Disadvantages of Butterfly valve

However, there are a few disadvantages of a butterfly valve as listed below

  • Throttling service is limited to low differential pressure
  • Disc movement is affected by flow turbulence.
  • The valve disc is always under pressure and can interrupt the flow even in an open position.
  • The possibility of Cavitation and choked flow is a concern
  • Poor Sealing function.
  • Not suitable for high differential pressure.

Butterfly Valve vs Gate Valve

The main differences between a butterfly valve and a gate valve are tabulated below

Butterfly ValveGate Valve
Butterfly valves provide obstructed flow even in a fully open position.The flow of gate valves is unobstructed in the fully open position.
Handling and installation of butterfly valves are quite easy. The handling and installation of gate valves are comparatively difficult.
Due to their smaller size butterfly valves need reduced space.As gate valves are bigger in size, more space is required to install them in a piping system.
Butterfly valves possess the comparatively less pressure-withstanding capability.Gate valves are suitable for high-pressure applications.
Due to the quick operation of butterfly valves, there is a possibility of a water hammer. As the gate valve operating time is more, there is less chance of surge.
Butterfly valves have a shorter shaft that is easily accessible.Gate valves possess a longer shaft with difficulty to access.
Due to the smaller size, the weight of butterfly valves is significantly less.Gate valves are heavy-weight valves.
Butterfly valves are cheaper.Gate valves are quite expensive compared to butterfly valves.
Table: Butterfly Valve vs Gate Valve

Ball Valve vs Butterfly Valve

The main differences between a butterfly valve and a ball valve are produced below in a tabular format.

Butterfly ValveBall Valve
Butterfly valves are disk-mounted.Ball valves are ball-mounted.
Pressure drop through butterfly valves is usually more.Ball valves provide less pressure drop as compared to butterfly valves.
Less sealing.More effective Sealing.
Butterfly valves are lightweight.Ball valves are significantly heavier.
Butterfly valves require less installation space.Ball valves need more space to install.
Butterfly valves are less costly as compared to ball valves.Ball valves are costly items as compared to butterfly valves.
Table: Butterfly Valve vs Ball Valve

Symbols of Butterfly Valves

The following symbols are used as butterfly valve symbols in piping isometric and P&ID.

Butterfly Valve symbol
Fig. 4: Butterfly Valve Symbol

Butterfly Valve Standard

Industrial Butterfly valves are designed based on the following butterfly valve standards

  • API 609
  • MSS SP-67
  • BS EN 593
  • ISO 5752
  • MSS SP-68
  • AWWA C504

Butterfly Valve Materials

The following materials are normally used for butterfly valve components

Butterfly Valve BodyDisc MaterialStem materialSeat material
Carbon SteelAluminumCast SteelNeoprene
Stainless SteelStainless SteelStainless SteelPTFE
Cart Iron   EPDM
Ductile iron  NBR
Cast Bronze  Viton
DSS  BUNA-N
Nickel Alloy/Hastelloy  Inconel (Metal Seat)
Titanium Alloy  Stainless Steel
Table: Butterfly Valve Materials

Data to be Provided for Butterfly Valve Manufacturer

The following data should be provided to the butterfly valve manufacturer while ordering

  • Flange rating/Pressure
  • Specific gravity, viscosity, material content, and the composition of the fluid to be handled.
  • Pressure drop or required Cv (maximum)
  • Flow rate
  • Design and operating temperatures
  • Piping moments
  • Valve body, Disc, Seat material
  • Valve plate material
  • Valve diameter or connected pipe diameter
Butterfly Valves in Operating Plant
Fig. 5: Butterfly Valves in Operating Plant

Butterfly Valve Working Principle

The butterfly valve operates based on the quick shut-off principle. The circular disc (butterfly) of the valve is placed in the center of the pipe which allows a rod to go through it to an actuator, on the outer side of the valve. Using the handwheel, the metal disc is rotated to keep the disc parallel or perpendicular to the flow and it allows or closes the flow. So, the operating principle of the butterfly valves is fairly simple. The animation below by the GEMU group clearly shows the butterfly valve working.

Working Principle of Butterfly Valve

Butterfly Valve Manufacturers

There are many butterfly manufacturers in this world. A list of a few of the world-renowned butterfly manufacturers is provided below:

  • Dezurik
  • Pentair Valves and Controls
  • Flowserve Corporation
  • Fisher Valves
  • Flomatic Valves
  • Crane Company
  • NIBCO
  • Bray Valves
  • Zwick
  • Kitz Corporation
  • Hobbs Valve
  • Apollo Valves
  • Kieselmann
  • Valworx
  • Davis
  • Velan
  • Emerson Electric Company
  • L&T Valves
  • Cameron
  • Amco Industrial Valves
  • VIP Valves

Properly selected and integrated with the latest controls and communications technology, butterfly valves can provide an economical, long-term solution to flow control in large process plants, the power industry, refineries, pulp, and paper manufacturing, and food and beverage processing.

Dynamic Analysis of Piping Systems

Dynamic analysis refers to the evaluation of how a piping system responds to dynamic loads. These loads can cause vibrations, stress fluctuations, or transient forces that static analysis cannot adequately capture. The main purpose of dynamic analysis is to ensure the safety, reliability, and integrity of piping systems under dynamic conditions and to prevent failures due to fatigue, resonance, or transient overloading. Some of the typical dynamic loads are seismic activity or earthquakes, water hammer or pressure surges due to sudden valve closures or pump trips, slug flow, pulsation from compressors or reciprocating machinery, wind or wave loads, vibration from rotating equipment, etc.

What is Dynamic Analysis of Piping System?

Dynamic Analysis is the study of a fluid-filled piping system to find the system response with respect to time. The dynamic behavior of the piping system is completely different from the static behavior. In static analysis, as the piping system gets enough time to respond against the unbalanced force, the static analysis does not create much problem. But in dynamic analysis, the impact of forces is quick, and the unbalanced force can create havoc causing the piping system to fail. In this article, we will explore the basics of dynamic analysis.

Static Analysis vs Dynamic Analysis

As stated earlier, the system response is completely different in both static and dynamic analysis. The main differences between the two analysis methods are tabulated below:

Static AnalysisDynamic Analysis
Static Analysis is not dependent on timeThe dynamic analysis depends on the time
In static analysis, the acceleration is negligibleEffects of acceleration are considered in dynamic analysis.
In static analysis, the piping System is in equilibrium with balanced forcesThe piping System is not in equilibrium in dynamic analysis, and it has unbalanced forces.
Boundary conditions are not dependent on time in static analysis.Boundary conditions are time-bound in dynamic analysis.
Table: Static vs Dynamic Analysis

In simple terms, a static load can be considered as a dynamic load with a long duration so the piping system can fully respond to it. In static analysis, force is not dependent on time and acceleration is negligible. Also, the time when it started is not important. The piping system is in equilibrium having balanced forces in the system and the boundary conditions are not dependent on time. It is believed that the load is applied very slowly and that the effect of time is negligible and not considered.

Whereas, in dynamic analysis, the load depends on time. The effect of acceleration is considered in dynamic analysis. Dynamic loading tends to increase the response of the structure beyond the response obtained if the same load is applied statically. The piping system is not in equilibrium, and there are some unbalanced forces between the pipe and the supports supporting it. The response of the system depends not only on the magnitude of the applied force but also on the frequency (i.e., the timing of the load).

Dynamic Modal Analysis

Every system has resonant frequencies, or the ability to vibrate at certain frequencies, without any external load being applied. The amplitude of the response is measured with frequency and as we approach the resonant frequency, the response becomes infinite, as can be seen from Fig. 1. With modal analysis, we are interested in the limits of the response of the system being analyzed. The natural frequencies are found using a stiffness matrix, Eigenvectors, and Eigenvalues. It is important for the users to understand why these frequencies are important and how to set up and analyze modal analysis in to get correct dynamic results, considering all possible parameters. When the natural frequency of the system coincides with the frequency of the externally applied load (that may be any dynamic load like wind, earthquake, slug force, pump vibrations, etc.) resonance condition occurs that leads to substantial damage to the system.

Amplitude vs Frequency Response
Fig. 1: Amplitude vs Frequency Response

Examples of Resonance causing damage

Here are some examples of resonance creating direct damage to the system.

1985 earthquake in Mexico City

The energy released during this earthquake was equivalent to 1114 nuclear detonations, and the earthquake was felt as far as Los Angeles. Up to the 1950s, no earthquake codes existed. It wasn’t until the later 1950s and 1970s that earthquake codes were developed and introduced for building construction. Despite this, none of these safety precautions accounted for an earthquake.

Impact of Resonance
Fig. 2: Impact of Resonance

During the earthquake, most of the 6 to 15-story high-rises collapsed (Fig. 2), resulting in a huge loss of life and property. Interestingly, buildings with less than 6 or more than 15 stories were not damaged as much, while buildings with 9 stories were destroyed to rubble! Two explanations were offered for the earthquake’s impact: the long duration of the shaking and the resulting resonance with the lakebed sediments. In other words, the resonant frequency of the 6 to 15-story structures coincided almost exactly with the frequency of the earthquake.

Tacoma Narrows Bridge – 1940 Disaster

Another real-life example is the Tacoma Narrows Bridge in Washington.

In November of 1940, the bridge instantaneously collapsed.  Investigation of the disaster revealed that the cause of the collapse was an aeroelastic flutter, or it was a wind-induced collapse.  The winds were blowing at a particular frequency, which happened to coincide with the resonant frequency of the structure, resulting in the sudden collapse of the structure.

Example of Resonance in Daily Life

We observe resonance examples in our day-to-day life as well.

The most familiar example is the playground swing. When we push the swing, it starts moving forward and backward. If a series of regular pushes are given to the swing, its motion can be built. The person who is pushing the string has to match the timing of the swing. The pusher has to sync with the timing of the swing. This causes the motion of the swing to have increased amplitude so as to reach higher. Once when the swing reaches its natural frequency of oscillation, a gentle push to the swing helps to maintain its amplitude due to resonance. We call this in-sync motion “Resonance.” But, if the push given is irregular, the swing will hardly vibrate, and this out-of-sync motion will never lead to resonance, and the swing will not go higher.

Resonance in day to day life
Fig. 3: Resonance in day-to-day life

You may also have noticed that the walls and furniture of your home vibrate when you play music on a heavy beat. This is because the natural frequency of the furniture gets resonated with the frequency of the sound of the music, and, hence, causes them to vibrate.

Dynamic Equation of Motion

Explaining Dynamic motion
Fig. 4: Explaining Dynamic motion

Figure (a) shows an example of a structure represented for dynamic analysis as a single-degree-of-freedom system i.e. structure modeled as a system with a single displacement coordinate. This single degree of freedom system is described conveniently with the mathematical model as shown in Figure (b) and can be written in the equation also called as ‘Dynamic Equation of Motion

Dynamic Equation of Motion

Fig (b) has the following components

  1. Mass element m represents the mass and inertial characteristics of the structure
  2. Spring element k represents the elastic restoring force and potential energy capacity of the structure
  3. A damping element c represents the frictional characteristics and energy losses in the structure
  4. And an excitation force F(t), representing the external force acting on the structural system

In the adoption of a mathematical model, it is assumed that each element in the system represents a single property, i.e., mass m represents the property of inertia, spring stiffness k exclusively represents the elasticity, whereas damper c represents energy dissipation. Such pure elements do not exist in the physical world, and this mathematical model is a conceptual idealization of the real structure

As the effect of frictional forces or damping is small, we are going to neglect it to explicitly solve this dynamic equation of motion. In addition to this, we consider the system, during its motion or vibration to be free from external action or forces or simply we can say under free vibrations.

Free Vibrations
Fig. 5: Free Vibrations

Under this condition, the system in motion is governed only by the influence of the initial condition i.e., displacement and velocity at time= 0. It is represented as xo here. By further solving this second degree of differential equation, we can find a solution for the angular frequency.

Once we get this angular frequency, the cyclic frequency can be calculated as 2 pi f. We can observe that the system characteristics of an SDOF oscillator can be completely described by its Natural Frequency and its damping value.

The free vibration response of any system with N degrees of freedom is the sum of N independent cyclic functions, known as modes of vibration, and each one has its own Natural Frequency and a single degree of freedom. The advantage of this is that each mode is independent and responds to external loads in the same way that an SDOF oscillator does.

Lumped mass model

In pipe stress analysis software, dynamic analysis is performed according to the finite element analysis (stiffness) method using a lumped mass model. With a lumped mass model, the mass of a particular pipe length is lumped at the endpoint only and not distributed equally along the pipe length. The flexible point needs a lower frequency, whereas a rigid point needs a higher frequency to extract your response. Hence, there are chances of missing responses at these rigid points. In real-life complex stress models, this becomes a severe problem due to the number of rigid supports and rigid points in the model.

In order to capture the spatial distribution of the inertial loads, the system must be properly discretized. This can be achieved by ensuring that mass points in the system are properly spaced. If this criterion is not satisfied, additional mass points should be added to refine the model. The time required to insert these piping points can be time-consuming and hence not reasonable for complex models.

Automatic Model Discretization in AutoPIPE

AutoPIPE provides options for refining a model automatically without having to define additional points. The system model is refined by generating mass points during the solution. These points are treated just like other points during the solution; however, they are not accessible for any other purpose. These points will not serve any function other than to provide better mass distribution of the model for dynamic loads.

If the initial distance between two adjacent points is greater than the optimum element length (Lopt), mass points are inserted in order to make the actual distance between points less than or equal to the optimum spacing.

The optimal length is calculated using Roark’s equation for a simply supported beam at both ends and dividing this value by 2 to refine it even further (refer to AutoPIPE help for detailed procedure).

Optimal length Calculation
Fig. 6: Optimal length Calculation

In AutoPIPE, the setting is available (Fig. 5) for this under the Edit model option as ‘Mass points per span’.

If 0 is entered, no mass point discretization will occur. This is the default.

If a value greater than 0 is entered, AutoPIPE will generate that number of mass points spaced equally between piping points (valid range is 1-9).

If A is entered, the number of mass points spaced equally between any two piping points will be generated automatically based on the dynamic properties of each pipe span and on the value entered in the “Cutoff frequency” field.

This cutoff frequency input is only available for input if Auto is entered for the “Mass points per span” field. The value entered at this prompt is used to determine the maximum number of mass points to be generated by AutoPIPE along a span of pipe and should (approximately) match the frequency of the biggest mode shape captured in the modal analysis.

We always recommend selecting ‘Auto’ to get more accurate results.

Modal Analysis in AutoPIPE

  1. Open Model in AutoPIPE from, File>Open.
  2. Go to Tools > Edit Option and make these changes:
    • Mass point per span (A-Auto, 0-None): A
    • Cutoff frequency: 100 (Fig. 7)

Then click OK to accept.

Dynamic Analysis Settings in AutoPIPE
Fig. 7: Dynamic Analysis Settings in AutoPIPE

Note: Specifying ‘A’ means that the mass spacing will be applied automatically using a frequency of 100Hz. It is possible to split each length into the same number of spans by using a number in the range 1-9 instead of A, but this can lead to very closely spaced nodes in short lengths.

  1. Go to Analysis > Dynamic analysis (Fig. 7) to set up dynamic analysis settings. Under Modal analysis, check on Analyze up to Cutoff frequency and Provide cutoff frequency value. Review other information if you want to make modifications over there. And then click ‘OK
  2. Then click on Analyze all from the Analysis ribbon. Make sure that Modal analysis is selected and click ‘OK
  3. To graphically review modal analysis results, go to Result > Interactive > Mode shapes. You can also animate these mode shapes to check the orientation of modes.
  4. You can also get detailed reports in text format. Go to Result > Output Report, select Frequency & Mode Shapes report, and click ‘OK’.

Results and Interpretation

AutoPIPE has automatically inserted intermediate-mass points as per minimum optimal length calculated from Roark’s formula as selected Auto for mass points per span in Edit Model Option.

You can also review the number of mass points inserted under each component by AutoPIPE from the Coordinate data listing. And can also review the total number of mass points (Fig. 8) from the Point summary report.

Mass Points in AutoPIPE
Fig. 8: Mass Points in AutoPIPE

AutoPIPE reports the same natural frequency for a particular piping system irrespective of the number of nodes in the system. Though you have a break element in-between, there won’t be a considerable change in natural frequencies. That issue you may have faced with our competitor software.

Output reports show these two reports for modal analysis. The frequency section lists the currently active range of natural frequencies calculated for the system by modal analysis. And Mode Shapes section lists the translation (mass normalized), and rotation point displacements for each active mode shape. These are not actual displacements, but the relative response if the system is excited from an external source.

Output Results
Fig. 9: Output Results

In the frequency report, you will see columns for participation factors and captured modal mass. 

The participation factor is a measure of the importance of the mode. The method used for calculating the participation factors is outlined in the program help. The mass participation report illustrates how sensitive each of the piping system’s modes is too dynamic loading. High modal participation factors indicate that the mode is easily excited by the applied dynamic forces. If subsequent displacement reports indicate high dynamic responses, then the modes having high participation factors must be dampened or eliminated. Once a particular mode is targeted as being a problem, it may be viewed in the mode shape report, or graphically via the animated mode shape plots.

The captured modal mass is another way of quantifying the importance of the mode and the two are related. The captured modal mass percentage tells how much of the response is attributed to a particular mode and also tells the mode orientation (X, Y, or Z). The more of the total system mass that is accounted for, the better is results. Due to the complexity of some piping systems, there may be a large number of DOFs and therefore insignificant modes, that would require a long solution time and it isn’t always practical to do this. We would want to achieve at least 75-80% where possible. But we need to use our engineering judgment on what percentage of captured mass is required and to decide how high to run on frequency.

Static Correction Methods

In order to capture the total dynamic response of a system, all modes of vibration in a system must be considered. The number of modes in a system is equal to the number of mass degrees of freedom in the system, so a typical system will have hundreds of modes of vibration. Modes whose frequency is close to the excitation frequency contribute the most to the response. For many dynamic loadings, the response of the system can be accurately predicted by considering the response of the first few modes. However, higher frequency modes may have a significant contribution to the response at a higher frequency.

Earthquake loading is a relatively low-frequency phenomenon and thus it is usual to only consider modes up to 33 Hertz. Higher frequency modes will not be excited significantly. Harmonic and impulsive loadings, on the other hand, may have high excitation frequencies and hence may excite higher frequency modes. For such loading, all modes with frequencies at least up to the excitation frequency should be extracted.

The extraction of all modes in a large system model can be logistically impractical. However, if only the first few modes of vibration are considered, the remaining modes which are neglected may cause a truncation error. This error is most noticeable in element forces and support reactions. The response of these modes can be approximated by applying a static correction. The amount of correction depends on the system and the excitation. All modes that are important to the response of a certain loading, should be extracted.

Static correction methods are approximate methods and may not be able to predict local responses. AutoPIPE provides the ability to perform two static correction procedures (Missing Mass, and Zero Period Acceleration).

By including Missing Mass Correction in the analysis, the following procedure is followed:

  • The amount of mass captured by all extracted modes is subtracted from the total mass.
  • The uncaptured mass is subjected to an acceleration equal to that at the cut-off frequency.
  • This uncaptured mass is considered another mode and combined with the others using the specified combination method selected.

The inclusion of Zero Period Acceleration (ZPA) can correct these missing modes and follows this procedure:

  • The entire structure mass is subjected to the peak ground acceleration
  • The static response is obtained for the structure
  • The larger the static and dynamic response is reported

In general, the missing mass method is more accurate than the ZPA method. The ZPA method is generally more conservative. Using either method is preferable to a truncated modal solution with no correction. Using both methods together is not recommended as it produces overly conservative results.

Few more related article for you:

What is Modal Analysis: Modal Analysis Example
What is Acoustic-Induced Vibration or AIV?
Flow-Induced Vibration (FIV)
Basics of Vibration Monitoring: A presentation
Piping Vibration: Causes and Effects
Solving vibration problems in a two-phase flowline

Recorded Webinar on Dynamic Analysis

The above article is prepared by Mr. Manoj Kale, Application Engineer in Bentley Systems. He presented the above subject in a webinar. Register here to watch the webinar and learn directly from the expert.

Online Course on Fundamentals of Dynamic Analysis (Caesar II)

There is a very good online course available on Fundamentals of Dynamic Analysis that explains the background theories and application of dynamic analysis using the Caesar II software. It covers the following details:

  • Single degree of freedom –Undamped system
  • Critically damped system
  • Overdamped system
  • Underdamped system
  • Forced vibration
  • Solution to the equation for forced vibration
  • Responses in forced vibration- with and w/o damping
  • The relation between phase and resonance
  • Multi-degree of freedom MDOF
  • Expanded version of the MDOF Matrix equations.
  • Example to demonstrate the concept of mass and stiffness matrices
  • Damping models
  • Harmonic analysis- Caesar II
  • Response spectrum
  • Dirac delta function and impulse response function
  • Response to arbitrary force
  • Response to step force
  • Response to half-cycle sinusoidal force
  • Response to symmetrical triangular pulse
  • Eigenvalue problem and Concept of modal orthogonality
  • Physical meaning of the matrix of mode shapes
  • Dynamic analysis of seismic inertial loading-Time history
  • Concept of ground motion and structural response
  • Mass participation percentages
  • Seismic response spectrum analysis
  • Seismic displacement spectrum and pseudo-acceleration spectrum
  • Concepts in seismic response spectrum analysis
  • Analysis of Seismic loads –Calculation of seismic inertial loading from ASCE-7-2022
  • Concept of ductility reduction factor
  • Seismic analysis- Inertial load calculation
  • Response spectrum, modal, spatial, and directional combinations
  • Seismic response spectrum in CAESAR II
  • Load cases – seismic spectrum
  • Control parameters and advanced control parameters
  • Highlights from the upcoming B31E on modal and directional combination methods
  • What is Seismic anchor movement?
  • Seismic analysis results- participation factors
  • Shock or Dynamic load factor spectrum for multi-degree of freedom systems
  • Force spectrum method
  • Fluid hammer –pressure variation
  • Force vs time- data used to generate DLF spectrum
  • Time history analysis- Caesar II Input and Output
  • Wilson theta method
  • Fourier transformation
  • Random Vibrations
  • Probability distribution function
  • Concept of expectation values, variance, std. deviation and autocorrelation function
  • Concepts and equations relevant to frequency domain analysis
  • Broadband and white noise
  • Concept of impulse response function
  • Concept of input-output in frequency domain analysis
  • Measurement of vibration
  • Key objectives of the measurement of vibration
  • A schematic of vibration measurement of a rotating machine
  • Key points for consideration when measuring vibration
  • Displacement transducers
  • Velocity transducers
  • Seismometer and its working principle
  • Principle of the accelerometer
  • The overall scheme for signal processing
  • Schematic for data collection and analysis
  • Analog to Digital conversion
  • Nyquist frequency
  • Aliasing
  • Filtering- Low-pass, High-pass, and Band-pass filtering
  • Windowing
  • RMS VALUE
  • Crest factor and Kurtosis
  • Discrete and Fast Fourier Transform
  • Importance of segment size in FFT
  • The concept of averaging
  • Power spectral density
  • Averaging of spectra
  • Concept of overlapping
  • Short-term Fourier transform(STFT)
  • Proximity probe and orbit plot
  • Bode plot and Polar plot
  • 2D & 3D Waterfall spectra
  • Vibration measurement in bearings and shaft-rotating equipment
  • Causes of vibration in rotating machines
  • Misalignment types
  • Piping vibration- Energy Institute Guideline
  • Dynamic strain measurement
  • Viscous dampers
  • AIV-Theory
  • FIV-Theory
  • Concepts and examples of fluid dynamics, monopole, dipole, and quadrupole
  • Beam and shell modes of vibration

If you are intersted for that course, you can enroll by visiting the following webpage: https://www.everyeng.com/learn/12af6c82/

Questions and Answers from the Fundamentals of Dynamic Analysis Course

Q1. Explain the term degree of freedom with an example. Why is the word ” independent” used in the definition? 

Ans: The degree of freedom means the number of independent ways by which a point can be displaced. The word intendent means, for e.g. Displacement in x direction is say not dependent on displacement in y direction. In terms of CAESAR II, when we say each node has 6 degrees of freedom, all we mean is that the node can have dx, dy,dz,rx,ry,rz movements and these are not dependent on each other.

Q2. Explain the terms mass matrix and stiffness matrix?

Ans: Imagine a structure of N DOFs. If we give unit acceleration to a DOF then the inertia forces that develops in all the DOFs forms a column of a mass matrix. If the process is repeated for all DOFs, then we get the complete mass matrix. Similarly, if we apply unit displacement by that we mean translation or rotation to a DOF and keep all other DOFs fixed then the forces /moments that develop in all DOFs forms a column of the stiffness matrix. Repeating this process for all DOFs generates the stiffness matrix.

Q3. What is meant by mode shape? 

Ans: The pattern of deformation of a body when its vibrating in a particular natural frequency.

Q4. What is modal orthogonality and what is its use? 

Ans: Modal orthogonality mathematically means that the matrix multiplication

Physical meaning- inertia forces for n th mode does zero work in going through r th mode displacements. Stiffness force for n th mode does zero work in going through r th mode displacements.

Q5. Explain how phase angle Changes with damping ratio?

Ans: Its 90 degree at w/wn i.e. at resonance and changes 180 across the resonance situation.

Q6. Explain key differences between overdamped, underdamped and critically damped system?

Ans: Overdamped is when ratio of damping to critical damping is >1. When this ratio is 1.0, its critical damping. When this ratio is less than 1.0 its underdamping. Both overdamped and critically damped system shows exponential decay of amplitude of vibration. Underdamped systems show sinusoidal behaviour with reducing amplitude with every cycle.

Q7. How does damping affect response? 

Ans: By reducing amplitude of vibration and introduce phase difference between input and response.

Q8. What is the key difference between lumped and consistent mass matrices?

Ans: Lumped mass matrices are diagonal. Consistent mass matrices are not diagonal. Consistent mass matrices are based on the satisfaction of physical laws of nature; lumped mass matrices are based on approximately sharing mass into equal proportions between DOFs.

Importance of Bourdon Effect, True and Effective Axial Force

Bourdon Effect on Pipelines

Bourdon Effect is associated with the pressure elongation of the piping and pipeline systems. In piping and pipeline systems, elbows or bends are frequently used for changing the direction of the pipe. The behavior of elbows and bends subjected to internal pressure is quite different as compared to a straight pipe. Due to the difference between the intrados and extrados surface area of bends, the pipe starts to straighten out by the unbalanced force arising from the internal pressure. This tendency of pipe bends to open up under internal pressure force is terms as the Bourdon effect. Also, the unbalanced pressure thrust force causes the straight pipe to elongate.

Traditionally, the impact of the bourdon effect is not considered for steel piping systems as the effect is negligible. However, with an increase in pressure and pipe length, specifically for long pipeline systems this effect is considerable and must be used in the analysis to avoid unanticipated deformations and high stresses at elbows. At the same time for analyzing plastic piping systems like PE, HDPE, GRE, FRP, and GRP systems, the bourdon effect must be considered.

Background of Bourdon effect in PASS/START-PROF

PASS/START-PROF always takes into account the Bourdon effect. By default, the option is made on and the users can’t turn it off. We insist on it because we had a lot of situations when users forgot to take this effect into account where it was really needed: for high-pressure piping systems and pipelines, HDPE, FRP, GRP, and GRE piping. This rule is needed for safety and provides protection from human mistakes.

But this decision produces a lot of questions from our PASS/START-PROF software users who think that the pipe support load is “incorrect” from their point of view, or thinks that equilibrium conditions are “not satisfied” between the anchor load and the internal force in the connected pipe.

After discussions with our customers, We realized that a lot of experienced engineers confuse about the understanding of the pressure thrust effect and how it should be used for support and nozzle load calculation, buckling calculation, flange leakage calculation, and stress calculation. A lot of people think that pressure doesn’t produce any deformations and loads at all.

I have to explain it every time, again and again to each customer within software technical support.

Finally, I decided to make a poll on the social media platform LinkedIn with the following simple question (Fig. 1).

Poll Output in LinkedIn
Fig. 1: Poll Output on LinkedIn

The result was stunning. The distribution of votes was almost even. So I decided to write this article to help piping engineers understand this phenomenon better. And also explain how PASS/START-PROF software deal with it.

The Pressure Effect Problem Description

The problem from the above poll (Fig. 1) can be illustrated with the following picture:

Impact of Internal Pressure on Restrained Pipe
Fig. 2: Impact of Internal Pressure on Restrained Pipe

In the beginning, please read the first part of this article about a restrained, unrestrained, and partially restrained pipe. I will show here (Fig. 3) only the final table with the equations.

Impact of Internal Pressure on Unrestrained, Fully Restrained and Partially Restrained Pipe
Fig. 3: Impact of Internal Pressure on Unrestrained, Fully Restrained and Partially Restrained Pipe

The pipe axial force equation is following:

If the thermal expansion is zero, then the internal force from “pure” pressure will be positive, i.e. tensile. So the correct answer in the above poll (Fig. 1) is “Tensile”.

In the literature the force “N” is called the “True Axial Force”, and the force “R” is called the “Effective Axial Force”. I didn’t know that before, until one day while I had a conversation with my customer got my attention to this fact. That’s why I call these forces just “Axial Force, N” and “Support Load, R”.

“True” and “Effective” Axial Force

The support load equation “R” from the table above is called in the literature an “Effective Axial Force”. The axial force “N” is called the “True Axial Force”.

For the example model from the poll the “Effective Axial Force” can be interpreted as “compressive”, because it produces the loads that push the anchors apart:

But this is just a fictitious definition. The real axial force “N” in the pipe wall will be tensile.

The “True Axial Force” (Axial Force “N” in the table above) is used for:

  • Axial pipe stress calculation.
  • Local pipe wall buckling analysis.
  • Pipe element internal forces. The checkbox “Nozzle Loads” should be unchecked as shown below
Internal Forces in Piping Element Table
Fig. 4: Internal Forces in Piping Element Table

The “Effective Axial Force” (Support Load “R” in the table above) is used for:

  • Loads on the support calculation.
  • Loads on Pressure Vessel and Tank Nozzles, Rotating Equipment Loads, etc.
  • Flange Leakage Check.
  • Pipeline upheaval buckling calculation.
  • Pipeline global buckling (Euler buckling) calculation.
  • Pipe element internal forces. The checkbox “Nozzle Loads” should be checked

Why the “Effective Axial Force R” should be used to calculate the nozzle loads, flange check, and global buckling instead of the “True Axial Force N”?

If the left end of the pipe in the picture below is connected to the pressure vessel nozzle or rotary equipment, then the “true” axial force in the equipment nozzle will be N (see table above). But when equipment manufacturers calculate allowable loads using finite element software like PASS/NOZZLE-FEM, they assume that the nozzle has the end cap and the vessel is under pressure. This means that axial stress caused by pressure thrust is already taken into account when nozzle allowable loads were calculated and should not be considered twice.

Hence we must exclude the pressure thrust load from the True Axial Force and use this value to compare with the nozzle allowable loads. This means that we must use the Effective Axial Force “R” for equipment nozzle checks. For example, if we connect a pipe with the end cap to the nozzle, the true True Axial Force in the nozzle wall will be

But we should exclude the pressure thrust component from this force i.e. use the Effective Axial Force that equals zero. Just imagine that the nozzle and the pipe both have the end caps like in the picture above. Therefore the nozzle load will be zero.

The same explanation can be offered for the flange leakage check. If you look at the equivalent pressure method equation, you will see, that the internal pressure is already taken into account and we should apply only additional loads, caused by thermal expansion and other influences, but not by the pressure of the thrust.

But why we should use the “Effective Axial Force” for global buckling and for upheaval buckling calculation, but at the same time use the “True Axial Force” for local pipe wall buckling? This phenomenon is a little bit harder to explain. I will try to do it using simple examples.

To calculate the longitudinal buckling we need to consider the deflected pipe shape, not the initial (installation) shape. To explain this effect, let’s look at this simple model, consisting of the two pipes

  • (a) The “cap pressure” forces acting on the pipe ends P·A as a result of summing the vectors produce the force “S” that tends to push the pipe in the lateral direction.
  • (b) If we represent the pipe as a polygonal chain, then at each turn of the pipe we will have a lateral force “S” trying to push the pipe away.
  • (c) And finally, if we will represent the pipe as the infinite number of polygons, we will have a uniform lateral load “S” that leads to pipeline global buckling.

I will pass the derivation of equations process, you can find it in the literature and just say the final conclusion is that the effective axial force “R” should be compared with the critical axial force value, not the true axial force “N”. For elastic buckling, without the soil resistance and thermal expansion Euler’s equation will be:

The additional “cap pressure” force generates the distributed load “S”.

This phenomenon can be explained by the fact that in the deflected form, the outer pipe wall length is longer than the internal wall length, hence the total pressure force on the outer surface is greater by the “S” value.

Also, the next analogy helps to understand this phenomenon. Imagine the restrained pipe under the pressure just like the reinforced concrete beam. The pipe is playing the role of the reinforcing bar (stretched) and the pipe content (water) buckling happens just like the compressed rod (see the picture below).

The global buckling is checked using START-Elements procedure.

I hope this article will help engineers to understand the Bourdon effect better and critically review the results obtained from the various pipe stress analysis software.

Here is the video that demonstrates how the pipe buckling due to internal pressure caused the Deepwater Horizon Blowout, which resulted in the deaths of 11 workers and caused a massive, ongoing oil spill into the Gulf of Mexico. 

To listen to the author about the above article and learn follow the following video post:

Video: Importance of the Bourdon Effect

Types of Pipe Flanges for Piping and Pipeline Systems

A pipe flange is a circular disc-shaped piping component that attaches to a pipe for blocking or connecting other components like valves, nozzles, special items, etc. After welding, piping flanges are the most popular pipe joining methods. Wherever, any dismantling of components is required for maintenance, inspection, replacement, or operational purposes piping flanged joints are preferred.

Pipe flanges use bolts and gaskets in between to ensure leakage-free piping joints. Piping flanges are selected based on pressure-temperature rating and pipe class following ASME B16.5 or ASME B16.47 standard. However, custom-made pipe flanges can be manufactured but are not preferred in industries. Piping flanges are the best alternative to welding or threading and are manufactured by forging.

Types of Flanges

Various types of pipe flanges are used in industries. They can be classified based on

Pipe Flange Types Based on Pipe Attachment or Connection

Depending on the type of pipe connection the piping flanges can be classified as below:

Weld Neck Flanges

Weld Neck Flanges
Fig. 1: Weld Neck Flanges

Weld neck pipe flanges are suitable for high-temperature and pressure applications. The neck of the pipe flanges is welded to the neck of the pipe.

The main features of weld neck flanges are:

  • Weld neck flanges (Fig. 1) have a long tapered hub between the flange ring & weld joint; Hence, these flanges are referred to as high hub flanges. This hub provides a more gradual transition from the flange ring thickness to the pipe wall thickness and the ID matches with the pipe ID. This smooth transition of weld neck flanges reduces high-stress concentrations and consequently increases the strength of the flange.
  • As Pipe ID and Flange ID match, there are no flow restrictions. At the same time erosion and turbulence are eliminated.
  • Weld neck flange is considered the best-designed butt welded flange available in the piping industry. The welding area, being sufficiently away from the face avoids undue distortion.
  • This type of flange is attached to the pipe by having a butt weld which can be radiographed if required.
  • Weld neck flanges are suitable for extreme service conditions to handle repeated bending from line expansion, contraction, or other external forces.
  • This type of flange is recommended for the handling of costly, inflammable, or explosive fluids where failure or leakage of a flange joint might bring disastrous consequences.
  • The pipe Schedule number and I.D. or O.D. must be provided while ordering weld neck pipe flanges.
  • The welding neck flange needs accurate alignment of bolt holes before welding.
  • However, Weld Neck flanges (Fig. 2) are expensive as compared to other flange types.
  • Weld neck flanges require more space and are bulky. Highly skilled manpower is required for the fabrication of welding neck flanges.
  • Weld Neck Flange is available in all sizes & it can be Flat Face, Raised Face, or Ring Type Joint type.
  • Butt-weld fittings like elbows, tees, or reducers can be directly welded to the weld neck flange without requiring any pipe spool in between.
Details of Welding Neck Flanges
Fig. 2: Details of Welding Neck Flanges

Slip-On Flanges

Slip-on pipe flanges are shorter in length than the weld neck flange so can be used where there is a space constraint. The inside diameter of slip-on flanges is slightly larger than the pipe OD and so it can slide over the pipe. They are secured to the pipe using two fillet welds from inside and outside. The Slip-on type of flange is widely used in lower temperatures and pressure applications because of its low initial cost. However, their life span is around one-third that of the weld neck flange.

Slip on Flange
Fig. 3: Slip on Flange

The main features of slip-on flanges are:

  • The strength of the slip-on flange (Fig. 3) is around two-thirds that of a corresponding welding neck flange.
  • The slip-on flange is not recommended for corrosive and/or critical services.
  • The use of slip-on flange is usually limited to class 300 (refer to para on pressure-temperature rating) and design temperature not exceeding 500° F.
  • Proper alignment of bolt holes must be ensured before the welding of this type of flange.
  • The joint in a slip-on flange can not be subjected to radiography due to the absence of a full penetration weld.
  • slip-on flanges are not suitable for cyclic loading services.
  • Less skilled manpower is required during installation due to the use of fillet welds. The fillet weld size on the inside of the flange is equal to the pipe wall thickness, or 6mm; whichever is lower.

Lap Joint Flange

A lap joint flange is basically a two-component flange assembly. It has a stub end and a backing lap-joint ring flange. A pipe is butt-welded to the Stub End and the Lap Joint is free to rotate around the stub end. The face of the stub end acts as a raised face of the flange and can be of different materials to save cost. Only the stub end comes in contact with the fluid.

Lapped joint Flange and Blind flange
Fig. 4: Lap Joint Flange and Blind Flange

The main features of a lap joint flange are:

  • Lap joint flanges are used as a combination with a lap joint stub.
  • Lap joint flanges (Fig. 4) are a good alternative to costly flanges required for process design conditions. An ordinary steel flange behind the lap on alloy and stainless steel pipe without sacrificing internal corrosion protection can be used.
  • In plastic piping systems, Lap joint flange is used.
  • These flanges are comparable to slip-on flanges with respect to pressure-withstanding capability.
  • The major disadvantage of lap joint flanges is that it has only about 10% of the fatigue life of welding neck flanges. That is why these flanges are not used where severe bending stresses exist.
  • This type of joint avoids the necessity of accurate alignment of bolt holes since the flange is free to revolve on the pipe. So these flanges can be readily aligned with bolt holes of the mating flange.
  • These types of flanges are also useful in cases where frequent dismantling for cleaning or inspection is required or when it is necessary to rotate the pipe by swiveling the flange.

Blind Flange

A blind flange is a solid flange and without the central hole used to seal or block off a section of pipe or a nozzle on equipment that is not used. Blind flanges are designed robustly as they have to withstand remarkable pressure stress. However, they don’t have to absorb thermal stresses as they are free to expand as attached at the end of the piping connection.

The weight of blind flanges (Fig. 4) is normally more than other flange types. They are frequently used during pressure testing of piping systems. Blind flanges can be of Flat or Raised Face type.

Socket Weld Flange

Socket Weld flange and Threaded Flange
Fig. 5: Socket Weld flange and Threaded Flange

Socket weld flanges use only one fillet weld on the outer side of the flange. As per ASME B31.1, in a socket weld flange connection, the pipe is inserted in the socket at first until it reaches the flange bottom and then it is lifted by 1.6 mm and finally fillet welded. This 1.6 mm gap is kept to allow proper pipe positioning inside the flange socket after the weld solidification.

Socket Weld Flanges are suitable for small-size pipes (up to 2″) and are not recommended for severe services. They can be used for high-pressure piping that does not transfer highly corrosive fluids as fluid accumulation inside the gap will easily corrode the pipe.

From a strength point of view, socket weld flanges (Fig. 5) are comparable to slip-on flanges.

Threaded or Screwed Flange

Threaded flanges are joined to pipes by screwing the pipe and are used on piping systems that prohibit direct welding on the pipe. Usually, threaded flanges are used for Galvanized Piping. Industrial Threaded flanges are made in sizes up to 4 inches with various pressure ratings. Their use is mostly limited to small pipe sizes carrying low-pressure temperature fluids.

Threaded flanges (Fig. 5) are frequently used in areas containing explosives. Cutting thread on very thin pipes is difficult, threaded flanges are used on relatively thicker pipes. The main features of screwed flanges are:

  • The attachment process or joining method is quick.
  • The threads are prone to leakage under cyclic loading, hence not recommended for cyclic services.

Pipe Flange Types Based on Flange Facing

Based on Flange Facings, the flanges are classified as

Flange Types based on Flange faces
Fig. 6: Flange Types based on Flange Faces

Types of Pipe Flanges Based on Pressure-Temperature Rating

Based on pressure-temperature rating flanges are of the following types:

  • 150#
  • 300#
  • 400#
  • 600#
  • 900#
  • 1500#
  • 2500#

With an increase in pressure rating the flange dimensions, strength, and load-carrying capacity increase. Click here to know more about the pressure-temperature rating and flange rating.

Flange Types based on Governing Design Code

Based on governing design code piping flanges can be grouped into the following classes

  • ASME/ANSI Flanges (ASME B 16.1, ASME B 16.5, ASME B 16.42, ASME B 16.47)
  • BS Flanges (BS 10, BS 1560)
  • API Flanges (API 6A, API 17D)
  • DIN flanges
  • Custom made flanges, etc

Additionally, based on the pipe flange material of construction they can be classified as

  • Metallic Flanges
    • Carbon Steel Flanges
    • Alloy Steel Flanges
    • SS/DSS Flanges
    • Cast Iron Flanges
    • Ductile Iron Flanges
  • Non-Metallic Flanges (FRP/GRP/GRE Flanges)

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Methods for Checking Flange Leakage
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Guidelines for Selection of Various Types of Flanges
Flange Bolt tightening Procedure/Bolt Tightening Steps

Difference Between ASME Sec VIII Div. 1 and Div. 2

Both ASME Sec VIII Div 1 and Div 2 are used for pressure vessel design. Both divisions contain mandatory requirements, specific prohibitions, and non-mandatory guidance for pressure vessel materials, design, fabrication, examination, inspection, testing, certification, and pressure relief. So in a broad sense, both may seem to be similar but there are few distinct differences between both Divisions. In this article, we will explore the major differences between ASME Sec VIII Div 1 and Div 2.

Typical Pressure Vessel
Typical Column (Pressure Vessel) during the erection stage

ASME Sec VIII Division 1 vs ASME Sec VIII Division 2

ASME Section VIII, Division 1 is a straightforward design-by-rule method used by engineers to design pressure vessels based on rules. It’s conservative and usually leads to a sturdier design.

ASME Section VIII, Division 2 requires more detailed calculations and allows vessels to handle higher stresses, making it suitable for vessels with specific purposes and fixed locations.

The key difference between Division 1 and Division 2 is in how they handle stress. Division 1 uses normal stress theory, while Division 2 uses maximum distortion energy theory (Von Mises). The major differences between the two divisions of ASME BPVC Sec VIII Div 1 and Div 2 are tabulated below:

ParametersASME Sec VIII-Division 1ASME Sec VIII-Division 2
Design ApproachASME Sec VIII Division 1 is focused on a design-by-rule approachASME Sec VIII Division 2 on the other hand, is based on a design-by-analysis approach
Design FactorThe design Factor used is 3.5 on tensile and other yields and temperature considerations.Design Factor of 3 (3.0 for Division 2, Class 1 and 2.4 for Division 2, Class 2) on tensile and other yield and temperature considerations.
Pressure LimitPressure typically up to 3000 psig. ASME Sec VIII Div 1 is more suitable for low-pressure applications.Pressure is usually 600 psig and larger (less than 10000 psi). ASME Sec VIII Div. 2 caters to high-pressure applications.
Design RulesMembrane – Maximum stress
Generally Elastic analysis.
Very detailed design rules with Quality (joint efficiency) Factors. Little stress analysis required; pure membrane without consideration of discontinuities controlling stress concentration to a safety factor of 3.5 or higher
Maximum Shear stress theory is the basis for Shell of Revolution.
Generally Elastic analysis Membrane + Bending. Fairly detailed design rules. In addition to the design rules, discontinuities, fatigue, and other stress analysis considerations may be
required unless exempted and guidance provided for in Appendix 4, 5 and 6.
Design Calculations Simple Calculations.requires more detailed calculations than Division 1
Failure Theory of DesignASEM Sec VIII Division 1 is based on the normal stress theoryASME Sec VIII Division 2 is based on maximum distortion energy (Von Mises criteria)
Experimental Stress
Analysis
Experimental methods of stress analysis are not required in normal cases.Experimental stress analysis is introduced and may be required
Material and Impact
Testing
Few restrictions on materials; Impact required unless exempted; UG-20, UCS 66/67 provides extensive exemptions.More restrictions on materials; impact
required in general with similar rules as Division 1.
NDE RequirementsIn ASME Sec VIII Div. 1, the NDE requirements may be exempted through increased design factors.Div. 2 has more stringent NDE requirements; extensive use of Radiographic tests, Ultrasonic Tests, Magnetic Particle Tests, and Penetration Tests.
Welding and
fabrication
Different types with butt welds and others.Extensive use/requirement of butt welds and full penetration welds including non-pressure attachment welds.
Fatigue EvaluationNot mandatory.AD 160 for fatigue evaluation
ManufacturerManufacturers are to declare compliance with the data report.Manufacturer’s Design Report certifying design specification and code compliance in addition to a data report.
Professional
Engineer
Certification
Normally not required.Professional Engineers’ Certification of User’s Design Specifications as well as Manufacturer’s Design Report
Professional Engineers shall be experienced in pressure vessel design.
Code Stamp and
Marking
U Stamp with Addition markings
including W, B, P, RES; L, DF, UB, HT, and  RT.
U2 Stamp with Additional marking
including HT.
Hydrostatic Test Pressure1.3 times design pressure.1.25 times design pressure.
Allowable Stress Value at a specified design temperatureLower, hence higher design margin.Higher, hence lower design margin.
Shell thickness at the same design pressureThickerThinner.
Material CostHigher.Lower.
Minimum Pressure Design Thickness Calculation Equationt=PD/2S – 1.2Pt=D/2{Exp(P/S)-1}
Hydrotest Stress CalculationIn ASME Sec VIII Division 1, hydro test stresses are not specifically limited, and partial penetration nozzle welds are permitted.In the ASME Sec VIII Division 2, hydro test stress calculations are mandatory as they are limited, and full penetration nozzle welds are required
No of Vessels produced AnnuallyLargerLower
Reference Standards ASME B 1.13M AND ASME B 1.21M related to Screw threads are not listed Both standards are given as references. 
Difference Between ASME Sec VIII Div. 1 and Div. 2