QUAD NEOM PIP FDR 001 Rev.0

NEOM 80 Inches Flange Design
As Per ASME VIII Div.1 App.2

QUAD-NEOM-PIP-FDR-001
Document history
Revision code Description of changes Purpose of issue Date

ISSUED FOR
00 29/04/2023
REVIEW
Document approval
Prepared by Reviewed by Approved by

Name JOSEPH SAMIR ISHAK MOHAMED ARAFA
Job Title QUAD PIPING LEAD QUAD PROJECT MANAGER

ENGINEER
DOCUMENT CODE : QUAD-NEOM-PIP-FDR-001 REVISION CODE: 00 P AGE 2 OF 47
©NEOM [2021]. All rights reserved.

TABLE OF CONTENTS
1. SCOPE AND GENERAL INFORMATION
2. INTERNATIONAL DESIGN CODES AND STANDARDS
3. REFERENCE PROJECT DOCUMENTS
4. DEFINITIONS AND NOTATIONS
5. BASIS OF DESIGN
6. INPUT CALCULATIONS DATA
7. QUAD CALCULATION SHEET RUNS:
8. FINAL DIMENSIONS OF FLANGES
9. ATTACHMENTS
DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 3 OF 47

1. SCOPE AND GENERAL INFORMATION:
1.1. This specification establishes the minimum requirements for the mechanical of non-standard
80 inches flange as per ASME VIII Div. 1 Appendix 2 “Rules for Bolted Flange
Connections with Ring Type Gaskets”.
1.2. The design should comply with all applicable projects, NEOM Water specifications, NEOM
Water datasheets, design office practices, and international codes and standards.
1.3. The rules in Mandatory Appendix 2 apply specifically to the design of bolted flange
connections with gaskets that are entirely within the circle enclosed by the bolt holes and
with no contact outside this circle.
1.4. The design of a flange involves the selection of the gasket (material, type, and dimensions),
flange facing, bolting, hub proportions, flange width, and flange thickness.
1.5. Flange dimensions shall be such that the stresses in the flange, calculated in accordance
with ASME VIII Div1 App. 2 (Part 2-7), do not exceed the allowable flange stresses specified
in 2-8.
1.6. All calculations were made on dimensions in the corroded condition considering corrosion
allowance of 3mm.
2. INTERNATIONAL DESIGN CODES AND STANDARDS:
The international design codes and standards used in this report, where applicable, are listed
below and specified in calculation sheet attached:
 American Society of Mechanical Engineers (ASME).

 American Society for Testing and Materials (ASTM).
 American Petroleum Institute (API).
 European Standards (EN).
3. REFERENCE PROJECT DOCUMENTS:
The NEOM project’s specifications and documents used in this report, where applicable, are
listed below:
 NEOM-NWA-SPC-2021-001 - Pipes and fittings Specification.

 NEOM-SP-PP-001 General Specifications for Piping and Fittings.
 00-180000-2500000948-CH2-PMN-RPT-000002 Rev.01
(Wall Thickness Calculation Report - Appendix A).

4. DEFINITIONS AND NOTATIONS:
The symbols described below are used in the equations for the design of flanges (see also
ASME VIII Div1 Appendix 2 - Figure 2-4):

5. BASIS OF DESIGN:
5.1. CIRCULAR FLANGE TYPES:
5.1.1. For purposes of computation, there are two main types:
(a) Loose Type Flanges:
 This type covers those designs in which the flange has no direct connection to the nozzle
neck, vessel, or pipe wall, and designs where the method of attachment is not considered
to give the mechanical strength equivalent of integral attachment. See Figure 2-4,
sketches (1), (1a), (2), (2a), (3), (3a), (4), (4a), (4b), and (4c) for typical loose type flanges
and the location of the loads and moments.
 Welds and other details of construction shall satisfy the dimensional requirements given
in Figure 2-4, sketches (1), (1a), (2), (2a), (3), (3a), (4), (4a), (4b), and (4c).

(b) Integral Type Flanges:
 This type covers designs where the flange is cast or forged integrally with the nozzle neck,
vessel or pipe wall, butt welded thereto, or attached by other forms of welding of such a
nature that the flange and nozzle neck, vessel or pipe wall is considered to be the
equivalent of an integral structure.
 In welded construction, the nozzle neck, vessel, or pipe wall is considered to act as a hub.
 See Figure 2-4, sketches (5), (6), (6a), (6b), and (7) for typical integral type flanges and
the location of the loads and moments.
 Welds and other details of construction shall satisfy the dimensional requirements given
in Figure 2-4, sketches (5), (6), (6a), (6b), and (7).
The code addresses a third type (Optional Type) which is neglected in this report as it
is only applicable where the pressure is equal or less than 300 Psi or 2 MPa which is
not confirming to NEOM Pipeline conditions of 40 Barg pressure.

5.2. BOLT LOADS:
In the design of a bolted flange connection, calculations shall be made for each of the two
design conditions of operating and gasket seating, and the more severe shall control
5.2.1. Design Conditions
(a) Operating Conditions:

 The conditions required to resist the hydrostatic end force of the design pressure tending
to part the joint, and to maintain on the gasket or joint‐contact surface sufficient
compression to assure a tight joint, all at the design temperature.
 The minimum load is a function of the design pressure, the gasket material, and the
effective gasket or contact area to be kept tight under pressure as per equation below,
and determines one of the two requirements for the amount of the bolting Am1.
(b) Gasket Seating Conditions:

 The conditions existing when the gasket or joint‐contact surface is seated by applying an
initial load with the bolts when assembling the joint, at atmospheric temperature and
pressure.
 The minimum initial load considered to be adequate for proper seating is a function of the
gasket material, and the effective gasket or contact area to be seated as per equation
below, and determines the other of the two requirements for the amount of bolting Am2.
 For the design of the flange, this load is modified to take account of the operating
conditions, when these govern the amount of bolting required Am, as well as the amount
of bolting actually provided Ab.

5.2.2. Total Required and Actual Bolt Areas, (Am and Ab):
 The total cross‐sectional area of bolts Am required for both the operating conditions and
gasket seating is the greater of the values for Am1 and Am2,
Where:
o Am1 = Wm1/Sb
o Am2 = Wm2/Sa.
 A selection of bolts to be used shall be made such that the actual total cross‐sectional
area of bolts Ab will not be less than Am.
5.2.3. Flange Design Bolt Load (W):
 The bolt loads used in the design of the flange shall be the values obtained from the
following equations:
(a) For operating conditions:
(b) Gasket Seating Conditions:

5.3. FLANGE MOMENTS:
 In the calculation of flange stress, the moment of a load acting on the flange is the product
of the load and its moment arm.
 The moment arm is determined by the relative position of the bolt circle with respect to
that of the load producing the moment
(a) For the operating conditions:

 The total flange moment Mo is the sum of the three individual moments MD, MT, and
MG, as defined in above paragraph # 4 “Definitions and Notations” on the flange design
load with moment arms as given in Table 2-6 of ASME VIII Div.1 Appendix 2 (Attached).
(b) For gasket seating conditions:

 The total flange moment Mo is based on the flange design bolt load.
5.4. CALCULATION OF FLANGE STRESSES:
 The stresses in the flange shall be determined for both the operating conditions and
gasket seating condition, whichever controls, in accordance with the following equations:
(a) For integral type flanges: (b) For Loose type flanges:

6. INPUT CALCULATIONS DATA:

7. QUAD CALCULATION SHEET RUNS:
7.1. INTEGRATED TYPE FLANGE (WELD NECK FLANGES):
1ST Run with assumed Flange Thickness of t= 160mm and Hub length of h=305mm

Doc No Sheet
Flange Calculation sheet 1/3

Bolted flange connections to ASME VIII, div. 1 Appendix 2 Rev. Date Made Check Appr.
Client NEOM Tag No QUAD-NEOM-PIP-FDR-001
Project NEOM PROJECT
Job No. QUAD-NEOM-2023
Location SAUDI ARABIA 0 2023.04.29 JB MA
Design Basis
Design Code:
ASME Boiler & Pressure Vessel Code - section VIII, Division 1, Appendix 2
Units of calculation Metric
Input Data
Variable Source of data Input Notes
Flange and Flange facing NEOM-NWA-SPC-2021-001 FF
Pipe Data Nominal Pipe Size NPD 00-180000-2500000948-CH2-PMN-RPT-000002 80"
Pipe Schedule Thickness 00-180000-2500000948-CH2-PMN-RPT-000002 20.6 mm
Flange Pressure Rating NEOM-NWA-SPC-2021-001 PN40
Pipe OD (actual) ODpipe NEOM-NWA-SPC-2021-001 2,032.0 mm
Pipe wall thickness (Uncorroded) tn NEOM-NWA-SPC-2021-001 20.6 mm
Length of flange hub h ASME B16.5 (min. hub length, 2.8.2) 305.0 mm
Flange thickness t Assumed by QUAD Team 160.0 mm
Bolt circle diameter PCD EN1092-1 2,300.0 mm
Hub Diameter (Largest) X EN1092-1 2,150.0 mm
Flange outside diameter A EN1092-1 2,425.0 mm
Bolts Bolt Standard ASME B1.1 Metric
Bolt Size (Specify M-Type , ISO)= dbolt EN1092-1 M64
Number of Bolts= nbolt EN1092-1 48
Bolt Root Area (per bolt) Abolt ASME B1.1 2,767.7 mm²
ASME VIII, table 2-5.1 Elastomers with mineral 1-ply

Gasket Gasket Type fiber fabric insertion gasket
Gasket diameter , MEAN(RTJ)/OD(RF): Vendor Data 2,168.0 mm
Gasket contact width w(RTJ) or N(RF) N Vendor Data 74.0 mm
Min. design seating stress y ASME VIII, table 2-5.1 26.0 N/mm²
Gasket factor m ASME VIII, table 2-5.1 2.75
Design Design Pressure P 00-180000-2500000948-CH2-PMN-RPT-000002 4.00 N/mm²
Conditions Design Temperature tmax 00-180000-2500000948-CH2-PMN-RPT-000002 70.0 ºC
Corrosion Allowance ca 00-180000-2500000948-CH2-PMN-RPT-000002 3.0 mm
External Axial Force (strain) Faxial N/A 0.0 N
Loads Moment Mx N/A 0.0 Nmm
Moment My N/A 0.0 Nmm
Moment Mz N/A 0.0 Nmm
Orientation of flange x,y,z N/A 0
Stresses Material Flange Selected by QUAD Team SA 105
At design temperature Sf_oper ASME B31.3 151.0 N/mm²
At ambient Sf_atm ASME B31.3 160.6 N/mm²
Material Bolting Selected by QUAD Team A193 B7 2.5"<d-<4"
At design temperature Sb ASME B31.3 Table A1 158.6 N/mm²
At ambient Sa ASME B31.3 Table A1 158.6 N/mm²
E Modulus Flange ASME II Part D 190,000.0 N/mm²
Conclusion
Flange design is acceptable for listed design pressure, However on margin

Bolting design is acceptable for design pressure
Bolting design is acceptable for gasket seating condition
Max. operating pressure before failure of flange or bolting is 5.0 N/mm²
Flange Thickness need to be increased to 220mm (min.)

Flange Rigidity Check, Rejected
Doc No Sheet

Bolted flange connections to ASME VIII, div. 1 Appendix 2
Calculations
Gasket key dimensions

Gasket outside diameter 2,168.0 mm
Basic gasket seating width b0 = N/2 (RF) Table 2-5-2 37.0 mm
Effective gasket seating width b=b0 for b0 < 1/4"
or b = 0.5(or 2.52 for metric) * (b0)^0.5 for b0 > 1/4" Table 2-5-2 16.0 mm
Gasket load reaction diameter G = mean gasket diameter for b0 < 1/4"
or G = Gasket OD - 2*b for b0 > 1/4" 2,136.0 mm
Flange values
Thickness of hub at small end g0 = tn - ca = 17.6 mm
Thickness of hub at back of flange g1 = (X-B)/2 = 76.6 mm
Radial dist. from PCD to large hub diam. R = (PCD-X)/2 = 75.0 mm
Inside diameter of flange B (Corroded ID) = ODpipe - 2 * g0 = 1,996.8 mm
Equivalent Working Pressure using Kellogs Method

Resulting Bending Moment Mres = No external Forces Specified 0 Nmm
Equivalent Pressure Peq = 16 * Mres / (π * G3 ) + 4 * Faxial / (π * G2 ) 0.00 N/mm²
Calculation Design Pressure Pd = P + Peq 4.00 N/mm²
Load and Bolt Calculations

Total joint-contact surface compression load Hp = 2 * b * π * G * m * Pd = 2,360,878 N
Total hydrostatic end force H = π / 4 * G^2 * Pd = 14,326,237 N
Min. required bolting load for operating conditions Wm1 = Hp+H = 16,687,116 N
Min. required bolting load for gasket seating Wm2 = π * b * G * y = 2,790,129 N
Total required cross-sectional area of bolts Am = greater of Wm1/Sb or Wm2/Sa = 105,229 mm²
Total available cross-sectional area of bolts Abolts = 132,850 mm²

Flange design bolt load W = 0.5 * ( Am + Abolts ) * Sa = 18,877,163 N
Required bolt rootdiameter= = ( 4 * Am / ( nbolt * π ) )^0.5 52.8 mm
Flange Moment Calculations

Flange Loads Lever arm Flange Moments
Operating Conditions
HD = π / 4 * B^2 * Pd = 12,519,840 N hD = R + g1 = 151.6 mm MD = HD * hD = 1,898,007,767 Nmm
HG = Hp = 2,360,878 N hG = 0.5 * ( PCD - G) = 82.0 mm MG = HG * hG = 193,592,003 Nmm
HT = H - HD = 1,806,397 N hT = 0.5 * ( hD+hG ) = 116.8 mm MT = HT * hT = 210,987,203 Nmm
M0 oper = MD + MG + MT = 2,302,586,973 Nmm
Seating Conditions
HG = W = 18,877,163 N hG = 82.0 mm M0 atm = 1,547,927,400 Nmm
Bolt Spacing= = PCD * SIN(π / nbolt ) 150.4 mm

Bolt pitch correction factor CF = [bolt_spacing / (2 * dbolt + 6 * t / ( m + 0.5))]0.5 (or minimum 1.0) 1.00
Flange Factors from fig. 2-7.1 Flange factors involving H/H_0 or g1/g0 Stress formula factors
K =A / B 1.214 h0 = (B * go)^0,5 187.5 mm α = t * e +1 1.495
T 1.833 h / h0 1.627 β = 4 / 3 * e * t+1 1.660
U 11.103 g1 / g0 4.352 γ =α/T 0.816
Y 10.104 F 0.580 δ = t^3 / d 0.191
Z 5.212 V 0.030 λ = γ+δ 1.006
f 1.000 m0 =CF * M0 oper / B 1,153,139 N
e = F / ho 0.0031 mm-¹ mG =CF*M0 atm / B 775,204 N
Poisson's Ratio Assumed = 0.3 d = U / V * h0 * g0^2 21,491,045 mm³
Doc No Sheet

Calculations
SUMMARY OF STRESSES:
Calculated Allowable Accept
Operating
Longitudinal Hub Stress: SH=f * m0 / (λ * g1^2 ) = 195 N/mm² 1.5 * Sf oper = 227 N/mm² OK
Radial Flange Stress: SR = β * m0 / (λ * t^2 ) = 74 N/mm² Sf oper = 151 N/mm² OK
Tangential Flange Stress: ST = m0 * Y / ( t^2 ) - Z * SR = 68 N/mm² Sf oper = 151 N/mm² OK
Combined Stress: greater of (SH+SR) / 2 or (SH+ST) / 2 = 135 N/mm² Sf oper = 151 N/mm² OK
Bolt Stress Wm1 / Abolts 126 N/mm² Sb 159 N/mm² OK
Seating
Longitudinal Hub Stress: SH = f * mG / (λ *g1^2 ) = 131 N/mm² 1.5 * Sf atm = 241 N/mm² OK
Radial Flange Stress: SR =β * mG / ( λ * t^2 ) = 50 N/mm² Sf atm = 161 N/mm² OK
Tangential Flange Stress: ST = mG * Y / ( t^2 ) - Z * SR = 46 N/mm² Sf atm = 161 N/mm² OK
Combined Stress: greater of (SH+SR) / 2 or (SH+ST) / 2 = 91 N/mm² Sf atm = 161 N/mm² OK
Bolt Stress Wm2 / Abolts 21 N/mm² Sa 159 N/mm² OK
REVERSE CALCULATION - max operating pressure

m0 values due to allowable stresses:
Longitudinal Hub Stress: m01 = λ * g1^2 * 1.5 * Sf oper / f = 1,337,184 N
Radial Flange Stress: m02 = λ * t^2 * Sf oper / β = 2,342,970 N
Tangential Flange Stress: m03 = λ * t^2 * Sf oper / ( λ * Y-β * Z ) = 2,568,615 N
{
Combined Stress: largest of m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + Y / t^2 + β / (λ * t^2 ) ) = 480,507 N
m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + β / (λ * t^2 ) ) = 1,291,515 N
Select min. m01 to m04 m0 = 1,291,515 N

Max flange moment M0 = = m0 * B / CF = 2,578,897,122 Nmm
Max operating pressure P=

= 8 * M0 / [ π * (B^2 * ( PCD - (X + B) / 2) + 8 * b * G * m * (PCD - G) + (G^2 - B^2) * (PCD - (G + B)/ 2))] = 5.7 N/mm²
Bolting P= = Abolts * Sb / ( π * ( 2 * b * m * G + 0.25 * G^2 ) ) = 5.0 N/mm²
BLIND FLANGE THICKNESS CALCULATION: (3.5.5)

Minimum thickness of flange
(Operating - W=Wm1) eoper = ( 0.3 * G^2 * P / ( Sf oper ) + 1.909 * Wm1 * hG / ( Sf oper * G ) ) ^0.5 + ca 213.6 mm

(Seating - P=0) eoper = ( 0.3 * G^2 * P / ( Sf oper ) + 1.909 * W * hG / ( Sf oper * G ) )^ 0.5 + ca 98.7 mm
Max pressure for actual thickness

Operating pmax = (e - ca )^2 * Sf oper / ( 0.3 * G^2 + 1.909 * π * hG * (2 * b * m + 0.25 * G )) 4.0 N/mm²
Flange Rigidity Check (According to Appendix S)
Rigidity index J = 52.14 * M0 oper * V / ( λ * Emod * g02 * h0 * 0.3) = 1.08 < 1.0 => Rej.
2ND Run with assumed Flange Thickness of t= 220mm and Hub length of h=380mm

Doc No Sheet

Design Basis
Design Code:
Input Data
Flange thickness t From Calc. 220.0 mm
Elastomers with mineral
ASME VIII, table 2-5.1 1-ply
Conclusion
Flange design is acceptable for listed design pressure

Flange Design is ok
Doc No Sheet

Calculations

Flange values




M0 oper = MD + MG + MT = 2,302,586,973 Nmm
Seating Conditions

K =A / B 1.214 h0 = (B * go)^0,5 187.5 mm α = t * e +1 1.622
T 1.833 h / h0 2.027 β = 4 / 3 * e * t+1 1.829
U 11.103 g1 / g0 4.352 γ =α/T 0.885
Y 10.104 F 0.530 δ = t^3 / d 0.347
Z 5.212 V 0.021 λ = γ+δ 1.232
f 1.000 m0 =CF * M0 oper / B 1,153,139 N
Doc No Sheet

Calculations
Operating
Seating

{
m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + β / (λ * t^2 ) ) = 1,786,330 N





Rigidity index J = 52.14 * M0 oper * V / ( λ * Emod * g02 * h0 * 0.3) = 0.62 < 1.0 => OK
Final Run with assumed Flange Thickness of t= 270mm and Hub length of h=380mm

Doc No Sheet

Design Basis
Design Code:
Input Data
Flange thickness t Recommended 270.0 mm
Conclusion
Flange design is acceptable for listed design pressure

Flange Design is ok
Doc No Sheet

Calculations

Flange values




M0 oper = MD + MG + MT = 2,302,586,973 Nmm
Seating Conditions

K =A / B 1.214 h0 = (B * go)^0,5 187.5 mm α = t * e +1 1.763
T 1.833 h / h0 2.027 β = 4 / 3 * e * t+1 2.018
U 11.103 g1 / g0 4.352 γ =α/T 0.962
Y 10.104 F 0.530 δ = t^3 / d 0.641
Z 5.212 V 0.021 λ = γ+δ 1.603
f 1.000 m0 =CF * M0 oper / B 1,153,139 N
Doc No Sheet

Calculations
Operating
Seating

{
Combined Stress: largest of m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + Y / t^2 + β / (λ * t^2 ) ) = 1,151,898 N
m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + β / (λ * t^2 ) ) = 2,443,724 N





7.4. LOOSE TYPE FLANGE (SLIP-ON FLANGES):
Run with assumed Flange Thickness of t= 220mm and Hub length of h=130mm

Doc No Sheet

Design Basis
Design Code:
Input Data
Flange thickness t Assumed by QUAD Team 220.0 mm
Conclusion

Flange Design is Rejected

Flange Rigidity Check, Rejected
Doc No Sheet

Calculations

Flange values




M0 oper = MD + MG + MT = 2,023,329,524 Nmm
Seating Conditions

K =A / B 1.192 h0 = (B * go)^0,5 342.1 mm α = t * e +1 2.415
T 1.842 h / h0 0.380 β = 4 / 3 * e * t+1 2.887
U 12.272 g1 / g0 1.000 γ =α/T 1.311
Y 11.168 F 2.200 δ = t^3 / d 2.915
Z 5.762 V 3.800 λ = γ+δ 4.226
f 1.000 m0 =CF * M0 oper / B 994,265 N
Doc No Sheet

Calculations
Operating
Seating

{
m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + β / (λ * t^2 ) ) = 3,524,705 N





Rigidity index J = 52.14 * M0 oper * V / ( λ * Emod * g02 * h0 * 0.3) = 1.47 < 1.0 => Rej.
7.5. LOOSE TYPE FLANGE (SLIP-ON FLANGES):
Run with assumed Flange Thickness of t= 270mm and Hub length of h=130mm

Doc No Sheet

Design Basis
Design Code:
Input Data
Conclusion

Flange Design is OK
Doc No Sheet

Calculations

Flange values




M0 oper = MD + MG + MT = 2,023,329,524 Nmm
Seating Conditions

K =A / B 1.192 h0 = (B * go)^0,5 342.1 mm α = t * e +1 2.736
T 1.842 h / h0 0.380 β = 4 / 3 * e * t+1 3.315
U 12.272 g1 / g0 1.000 γ =α/T 1.485
Y 11.168 F 2.200 δ = t^3 / d 5.389
Z 5.762 V 3.800 λ = γ+δ 6.874
f 1.000 m0 =CF * M0 oper / B 994,265 N
Doc No Sheet

Calculations
Operating
Seating

{
Combined Stress: largest of m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + Y / t^2 + β / (λ * t^2 ) ) = 1,481,819 N
m04 = 2 * Sf oper / ( f / ( λ * g1^2 ) + β / (λ * t^2 ) ) = 5,966,779 N





8. SUMMARY AND CONCLUSION:
a) For Integrated Type Flange:

 The minimum accepted thickness shall be t=220mm and the hub length shall be
h=380mm to ensure that all stresses are within acceptable limits by appendix 2 of
ASME VIII Div.1
 QUAD team recommends to increase the flange thickness to be t=270mm to match
the loose type and unite the data for safe and better design.
b) For Loose Type Flange:

 The minimum accepted thickness will increase to be t=270mm instead of 220mm to
ensure that the calculated rigidity factor is less than 1 to be within acceptable limits by
appendix 2 of ASME VIII Div.1 while the hub length will be h=130mm
The maximum pressure for both flange’s design shall not exceed 50 barg.
c) For both Flange Types:
 The assumed flange material is ASTM SA 105 however as material ASTM SA 216 Gr.
WBC & ASTM SA105 are sharing the same mechanical properties, any of the above
mentioned materials can be used in maufacturing.
 Below table shows the mechanical properties for both materials.

9. FINAL DIMENSION FOR FLANGES:

Final Integrated Flange Type Data
Design Conditions Variable Source of data Input Notes
Flange facing NEOM-NWA-SPC-2021-001 FF
Nominal Pipe Size NPD 00-180000-2500000948-CH2-PMN-RPT-000002 80"
Flange and Pipe Data Pipe wall thickness (Uncorroded) tn NEOM-NWA-SPC-2021-001 20.6 mm
Flange thickness t Recommended 270.0 mm
Bolt Standard ASME B1.1 Metric
Bolts
Elastomers with mineral fiber fabric
Gasket Type ASME VIII, table 2-5.1 1-ply
insertion gasket
Gasket
Design Pressure P 00-180000-2500000948-CH2-PMN-RPT-000002 4.00 N/mm²
Design Conditions Design Temperature tmax 00-180000-2500000948-CH2-PMN-RPT-000002 70.0 ºC
Axial Force (strain) Faxial N/A 0.0 N
Moment Mx N/A 0.0 Nmm
External Loads Moment My N/A 0.0 Nmm
Material Flange Selected by QUAD Team SA 105
Stresses
Flange values

Resulting Bending Moment Mres = No external Forces Specified 0.0 mm
Equivalent Pressure Peq = 16 * Mres / (π * G3 ) + 4 * Faxial / (π * G2 ) 0.0 mm
Calculation Design Pressure Pd = P + Peq 4.0 mm

Total joint-contact surface compression load Hp = 2 * b * π * G * m * Pd = 2,360,878.1 mm
Total hydrostatic end force H = π / 4 * G^2 * Pd = 14,326,237.4 mm
Min. required bolting load for operating conditions Wm1 = Hp+H = 16,687,115.5 mm
Min. required bolting load for gasket seating Wm2 = π * b * G * y = 2,790,128.6 mm
Total required cross-sectional area of bolts Am = greater of Wm1/Sb or Wm2/Sa = 105,228.8 mm
Total available cross-sectional area of bolts Abolts = 132,849.6 mm
Flange design bolt load W = 0.5 * ( Am + Abolts ) * Sa = 18,877,163.4 mm

HD = π / 4 * B^2 * Pd = 12,519,840 N hD = R + g1 = 151.6 mm MD = HD * hD = 1,898,007,767.3 mm
HG = Hp = 2,360,878 N hG = 0.5 * ( PCD - G) = 82.0 mm MG = HG * hG = 193,592,002.6 mm
HT = H - HD = 1,806,397 N hT = 0.5 * ( hD+hG ) = 116.8 mm MT = HT * hT = 210,987,203.1 mm
M0 oper = MD + MG + MT = 2,302,586,972.9 mm
Seating Conditions
HG = W = 18,877,163 N hG = 82.0 mm M0 atm = 1,547,927,400.4 mm

Bolt pitch correction factor CF = [bolt_spacing / (2 * dbolt + 6 * t / ( m + 0.5))]0.5 (or minimum 1.0) 1.0 mm
K =A / B 1.214 h0 = (B * go)^0,5 187.5 mm α = t * e +1 1.8 mm
T 1.833 h / h0 2.027 β = 4 / 3 * e * t+1 2.0 mm
U 11.103 g1 / g0 4.352 γ =α/T 1.0 mm
Y 10.104 F 0.530 δ = t^3 / d 0.6 mm
Z 5.212 V 0.021 λ = γ+δ 1.6 mm
f 1.000 m0 =CF * M0 oper / B 1,153,138.5 mm
e = F / ho 0.0028 mm-¹ mG =CF*M0 atm / B 775,204.0 mm
Final Integrated Flange Type Data
Design Conditions Variable Source of data Input Notes
Flange facing NEOM-NWA-SPC-2021-001 FF
Nominal Pipe Size NPD 00-180000-2500000948-CH2-PMN-RPT-000002 80"
Flange and Pipe wall thickness (Uncorroded) tn NEOM-NWA-SPC-2021-001 20.6 mm
Bolt Standard ASME B1.1 Metric
Bolts
Elastomers with mineral fiber fabric
Gasket Type ASME VIII, table 2-5.1 1-ply
insertion gasket
Gasket
Design Pressure P 00-180000-2500000948-CH2-PMN-RPT-000002 4.00 N/mm²
Design Design Temperature tmax 00-180000-2500000948-CH2-PMN-RPT-000002 70.0 ºC
Axial Force (strain) Faxial N/A 0.0 N
Moment Mx N/A 0.0 Nmm
External Moment My N/A 0.0 Nmm
Material Flange Selected by QUAD Team SA 105
Stresses
Flange values

Resulting Bending Moment Mres = No external Forces Specified 0.0 mm
Equivalent Pressure Peq = 16 * Mres / (π * G3 ) + 4 * Faxial / (π * G2 ) 0.0 mm
Calculation Design Pressure Pd = P + Peq 4.0 mm

Total joint-contact surface compression load Hp = 2 * b * π * G * m * Pd = 1,923,601.7 mm
Total hydrostatic end force H = π / 4 * G^2 * Pd = 14,406,835.0 mm
Min. required bolting load for operating conditions Wm1 = Hp+H = 16,330,436.6 mm
Min. required bolting load for gasket seating Wm2 = π * b * G * y = 2,273,347.4 mm
Total required cross-sectional area of bolts Am = greater of Wm1/Sb or Wm2/Sa = 102,979.6 mm
Total available cross-sectional area of bolts Abolts = 132,849.6 mm
Flange design bolt load W = 0.5 * ( Am + Abolts ) * Sa = 18,698,824.0 mm

HD = π / 4 * B^2 * Pd = 13,003,447 N hD = R + g1 = 132.5 mm MD = HD * hD = 1,722,956,661.3 mm
HG = Hp = 1,923,602 N hG = 0.5 * ( PCD - G) = 79.0 mm MG = HG * hG = 151,964,532.7 mm
HT = H - HD = 1,403,388 N hT = 0.5 * ( hD+hG ) = 105.8 mm MT = HT * hT = 148,408,329.6 mm
M0 oper = MD + MG + MT = 2,023,329,523.6 mm
Seating Conditions
HG = W = 18,698,824 N hG = 79.0 mm M0 atm = 1,477,207,094.4 mm

Bolt pitch correction factor CF = [bolt_spacing / (2 * dbolt + 6 * t / ( m + 0.5))]0.5 (or minimum 1.0) 1.0 mm
K =A / B 1.192 h0 = (B * go)^0,5 342.1 mm α = t * e +1 2.7 mm
T 1.842 h / h0 0.380 β = 4 / 3 * e * t+1 3.3 mm
U 12.272 g1 / g0 1.000 γ =α/T 1.5 mm
Y 11.168 F 2.200 δ = t^3 / d 5.4 mm
Z 5.762 V 3.800 λ = γ+δ 6.9 mm
f 1.000 m0 =CF * M0 oper / B 994,265.1 mm
e = F / ho 0.0064 mm-¹ mG =CF*M0 atm / B 725,900.3 mm
10. Attachments

ASME BPVC.VIII.1-2019 2-5
Table 2-5.1
Gasket Materials and Contact Facings
Gasket Factors m for Operating Conditions and Minimum Design Seating Stress y
Gasket Min. Design Facing Sketch and
Factor Seating Stress y, Column in
Gasket Material m psi (MPa) Sketches Table 2-5.2
Self‐energizing types (O-rings, metallic, elastomer, other gasket 0 0 (0) … …
types considered as self‐sealing)
Elastomers without fabric or high percent of mineral fiber:

Below 75A Shore Durometer 0.50 0 (0) (1a), (1b), (1c),
75A or higher Shore Durometer 1.00 200 (1.4) (1d), (4), (5);
Column II
Mineral fiber with suitable binder for operating conditions:

1
/8 in. (3.2 mm) thick 2.00 1,600 (11) (1a), (1b), (1c),
1
/16 in. (1.6 mm) thick 2.75 3,700 (26) (1d), (4), (5);
1
/32 in. (0.8 mm) thick 3.50 6,500 (45) Column II
Elastomers with cotton fabric insertion 1.25 400 (2.8) (1a), (1b), (1c),
(1d), (4), (5);
Column II
Elastomers with mineral fiber fabric insertion (with or without wire reinforcement):
3‐ply 2.25 2,200 (15) (1a), (1b), (1c),
(1d), (4), (5);
Column II
2‐ply 2.50 2,900 (20)
1‐ply 2.75 3,700 (26)
Vegetable fiber 1.75 1,100 (7.6) (1a), (1b), (1c),

(1d), (4), (5);
Column II
Spiral‐wound metal, mineral fiber filled:

Carbon 2.50 10,000 (69) (1a), (1b); Column
Stainless, Monel, and nickel‐base alloys 3.00 10,000 (69) II
Corrugated metal, mineral fiber inserted, or corrugated metal, jacketed mineral fiber filled:
Soft aluminum 2.50 2,900 (20) (1a), (1b); Column
Soft copper or brass 2.75 3,700 (26) II
Iron or soft steel 3.00 4,500 (31)
Monel or 4–6% chrome 3.25 5,500 (38)
Stainless steels and nickel‐base alloys 3.50 6,500 (45)
Corrugated metal:
Soft aluminum 2.75 3,700 (26) (1a), (1b), (1c),
Soft copper or brass 3.00 4,500 (31) (1d); Column II
Iron or soft steel 3.25 5,500 (38)
Monel or 4–6% chrome 3.50 6,500 (45)
Flat metal, jacketed mineral fiber filled:

Soft aluminum 3.25 5,500 (38) (1a), (1b),
--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`---
Soft copper or brass 3.50 6,500 (45) (1c) [Note (1)],

Iron or soft steel 3.75 7,600 (52) (1d) [Note (1)],
Monel 3.50 8,000 (55) (2) [Note (1)];
4–6% chrome 3.75 9,000 (62) Column II
‫ﯾﮏ دو ﺳﻪ ﺻﻨﻌﺖ‬
399
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Copyright ASME International (BPVC)
Provided by IHS under license with ASME Licensee=Khalda Petroleum/5986215001, User=Amer, Mohamed
No reproduction or networking permitted without license from IHS Not for Resale, 07/02/2019 13:29:04 MDT
Table 2-5.2
Effective Gasket Width
Basic Gasket Seating Width, b o
Facing Sketch (Exaggerated) Column I Column II
(1a)
N
N
--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`---
(1b)
N
See Note (1)
w
(1c)
T
N w N
w
(1d)
T
See Note (1) N w N
w
(2)
1/ in. (0.4 mm) nubbin
64
N w N/2
w
(3)
1/
64 in. (0.4 mm) nubbin
N w N/2
(4)
See Note (1) N
(5)
See Note (1) N
(6) w
…
Effective Gasket Seating Width, b

b = bo, when bo ≤ 1/4 in. (6 mm); b = , when bo > 1/4 in. (6 mm)
401
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2-9 ASME BPVC.VIII.1-2019
Figure 2-7.1
Values of T, U , Y , and Z (Terms Involving K )
404
--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`--- 123sanat.com
Figure 2-7.2
Values of F (Integral Flange Factors)
GENERAL NOTE: See Table 2-7.1 for equations.
405
--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`---
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Figure 2-7.3
Values of V (Integral Flange Factors)

--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`---
406
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Figure 2-7.4 Figure 2-7.5

Values of FL (Loose Hub Flange Factors) Values of VL (Loose Hub Flange Factors)
--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`---
407
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Figure 2-7.6
Values of f (Hub Stress Correction Factor)
25
20
15
10
9
8
7
h
o
Bg
6 6
h
o
5 5
h
f
0
0. .05
0 10
0
4 0 .15 4
0. .20
0. 25
0. 30
0 5 3
0 .40
0. .45
3 3
50
60
2.5 0. 2.5
70
0.
80
2 2
0.
90
0.
00
1.5 1. 1.5
10
1.
20
1.
30
1 1. 1
1 1.5 2 3 4 5
g 1 /g o
f = 1 (minimum)
= 1 for hubs of uniform thickness (g 1 /g0 = 1)
= 1 for loose hubbed flanges
--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`---
408
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Table 2-7.1
Flange Factors in Formula Form
Integral Flange Loose Hub Flange
Factor F per Figure 2-7.2 is then solved by Factor FL per Figure 2-7.4 is solved by
Factor V per Figure 2-7.3 is then solved by Factor VL per Figure 2-7.5 is solved by
Factor f per Figure 2-7.6 is then solved by Factor f per Figure 2-7.6 is set equal to 1.
The values used in the above equations are solved using eqs. (1) The values used in the above equations are solved using eqs. (1)
through (45) below based on the values g 1, go, h, and ho as defined through (5), (7), (9), (10), (12), (14), (16), (18), (20), (23), and (26)
by 2-3. When g1 = go, F = 0.908920, V = 0.550103, and f = 1; thus below based on the values of g 1, go, h, and ho as defined by 2-3.
eqs. (1) through (45) need not be solved.
Equations
(1) A = (g 1/go) − 1
(2) C = 43.68(h/ho)4
(3) C 1 = 1/3 + A/12
(4) C 2 = 5/42 + 17A /336
(5) C 3 = 1/210 + A/360
(6) C 4 = 11/360 + 59A/5040 + (1 + 3A )/C
(7) C 5 = 1/90 + 5A/1008 − (1 + A )3/C
(8) C 6 = 1/120 + 17A /5040 + 1/C
(9) C 7 = 215/2772 + 51A /1232 + (60/7 + 225A /14 + 75A 2/7 + 5A 3/2)/C
(10) C 8 = 31/6930 + 128A /45,045 + (6/7 + 15A /7 + 12A 2/7 + 5A 3/11)/C
(11) C 9 = 533/30,240 + 653A /73,920 + (1/2 + 33A/14 + 39A 2/28 + 25A 3/84)/C
(12) C 10 = 29/3780 + 3A /704 − (1/2 + 33A/14 + 81A 2/28 + 13A 3/12)/C
(13) C 11 = 31/6048 + 1763A/665,280 + (1/2 + 6A /7 + 15A 2/28 + 5A 3/42)/C
(14) C 12 = 1/2925 + 71A /300,300 + (8/35 + 18A/35 + 156A 2/385 + 6A 3/55)/C
(15) C 13 = 761/831,600 + 937A/1,663,200 + (1/35 + 6A /35 + 11A 2/70 + 3A 3/70)/C
(16) C 14 = 197/415,800 + 103A/332,640 − (1/35 + 6A /35 + 17A 2/70 + A 3/10)/C
(17) C 15 = 233/831,600 + 97A /554,400 + (1/35 + 3A /35 + A 2/14 + 2A 3/105)/C
(18) C 16 = C 1 C 7C 12 + C 2 C 8C 3 + C 3C 8C 2 − (C 32C 7 + C 82C 1 + C 22C 12)
(19) C 17 = [C 4C 7C 12 + C 2C 8C 13 + C 3C 8C 9 − (C 13C 7C 3 + C 82C 4 + C 12C 2C 9)]/C 16
(22) C 20 = [C 1C 9C 12 + C 4C 8C 3 + C 3C 13C 2 − (C 32C 9 + C 13C 8C 1 + C 12C 4C 2)]/C 16
(25) C 23 = [C 1C 7C 13 + C 2C 9C 3 + C 4C 8C 2 − (C 3C 7C 4 + C 8C 9C 1 + C 22C 13)]/C 16
(26) C 24 = [C 1C 7C 14 + C 2C 10C 3 + C 5C 8C 2 − (C 3 C 7 C 5 + C 8C 10C 1 + C 22C 14)]/C 16
(27) C 25 = [C 1C 7C 15 + C 2 C 1 1 C 3 + C 6C 8C 2 − (C 3C 7C 6 + C 8C 11C 1 + C 22C 15)]/C 16
(28) C 26 = − (C/4)1/4
(29) C 27 = C 20 − C 17 − 5/12 + C 17C 26
(30) C 28 = C 22 − C 19 − 1/12 + C 19C 26
(31) C 29 = − (C/4)1/2
(32) C 30 = − (C/4)3/4
(33) C 31 = 3A/2 − C 17C 30
(34) C 32 = 1/2 − C 19C 30
(35) C 33 = 0.5C 26C 32 + C 28C 31C 29 − (0.5C 30C 28 + C 32C 27C 29)
(36) C 34 = 1/12 + C 18 − C 21 − C 18C 26
(37) C 35 = − C 18(C /4)3/4
(38) C 36 = (C 28C 35C 29 − C 32C 34C 29)/C 33
(39) C 37 = [0.5C 26C 35 + C 34 C 31C 29 − (0.5C 30C 34 + C 35C 27C 29)]/C 33
(40) E 1 = C 17C 36 + C 18 + C 19C 37
409
--`,``,``,,`,`,,````,`,``,,,`-`-`,,`,,`,`,,`---
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NEOM 80 Inches Flange Design

As Per ASME VIII Div.1 App.2

Revision code Description of changes Purpose of issue Date

Prepared by Reviewed by Approved by

Job Title QUAD PIPING LEAD QUAD PROJECT MANAGER

DOCUMENT CODE : QUAD-NEOM-PIP-FDR-001 REVISION CODE: 00 P AGE 2 OF 47

©NEOM [2021]. All rights reserved.

1. SCOPE AND GENERAL INFORMATION

2. INTERNATIONAL DESIGN CODES AND STANDARDS

3. REFERENCE PROJECT DOCUMENTS

4. DEFINITIONS AND NOTATIONS

6. INPUT CALCULATIONS DATA

7. QUAD CALCULATION SHEET RUNS:

8. FINAL DIMENSIONS OF FLANGES

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 3 OF 47

2. INTERNATIONAL DESIGN CODES AND STANDARDS:

 American Society of Mechanical Engineers (ASME).

3. REFERENCE PROJECT DOCUMENTS:

 NEOM-NWA-SPC-2021-001 - Pipes and fittings Specification.

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 4 OF 47

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 5 OF 47

5.1. CIRCULAR FLANGE TYPES:

5.1.1. For purposes of computation, there are two main types:

(a) Loose Type Flanges:

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 7 OF 47

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 8 OF 47

5.2.1. Design Conditions

(a) Operating Conditions:

(b) Gasket Seating Conditions:

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 9 OF 47

5.2.3. Flange Design Bolt Load (W):

(a) For operating conditions:

(b) Gasket Seating Conditions:

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 10 OF 47

(a) For the operating conditions:

(b) For gasket seating conditions:

5.4. CALCULATION OF FLANGE STRESSES:

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 11 OF 47

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 12 OF 47

7.1. INTEGRATED TYPE FLANGE (WELD NECK FLANGES):

DOCUMENT CODE: QUAD-NEOM-PIP-FDR-001 REVISION CODE:00 P AGE 13 OF 47

Flange Calculation sheet 1/3

Units of calculation Metric

ASME VIII, table 2-5.1 Elastomers with mineral 1-ply

Flange design is acceptable for listed design pressure, However on margin

Flange Thickness need to be increased to 220mm (min.)

Flange Calculation sheet 2/3

Gasket key dimensions

Equivalent Working Pressure using Kellogs Method

Load and Bolt Calculations

Total available cross-sectional area of bolts Abolts = 132,850 mm²

Flange Moment Calculations

Bolt Spacing= = PCD * SIN(π / nbolt ) 150.4 mm

Flange Calculation sheet 3/3

REVERSE CALCULATION - max operating pressure

Select min. m01 to m04 m0 = 1,291,515 N

Max operating pressure P=

BLIND FLANGE THICKNESS CALCULATION: (3.5.5)

Minimum thickness of flange