EPERC Bulletin Nr 3 1

Part I


Design Calculation
and Gasket Testing


EPERC Bulletin Nr 3 2
EVALUATION OF THE NEW EUROPEAN prEN 1591
FOR METAL FLANGE CONNECTIONS

(Summary from Evaluatie van de nieuwe Europese berekeningsmethodiek (prEN 1591) voor
metalen flensverbindingen, Doc.No. MF 98-40, J anuary 1999 by J.A. Ter Laak (KEMA),
C.J. Dekker (Continental Engineering), E.C. Dillingh (TNO Industrie), T. Muilman
(Stoomwezen), H. Ramakers (DSM), W.J. Stikvoort (NAM))



It is not clear what the optimum calculation method for flange design is. The interaction between
flange, gland and bolts is inadequately modelled in the various relevant codes. Moreover, there
are considerable discrepancies to be found between these codes. The Regulations of the Steam
Vessel Inspectorate, like other international codes, state minimum requirements directed to
strength. In practice, it turns out that leak-tightness is sometimes inadequately guaranteed by the
application of these regulations.

There are currently developments taking place in which more attention is being paid to the
sealing quality of flanged joints. One of these developments is the new draft standard prEN 1591.

This report contains a study of the basic principles and structure of prEN 1591. Moreover, a
number of flanged joints were selected to be calculated according to prEN 1591 as well as
according to traditional codes. The results of these calculations have been compared with one
another, and with the finite-elements calculations performed for the flanged joints selected. On
the basis of the calculated gland pressure distribution it is possible to predict leak-tightness.
Furthermore, a parameter study was conducted to investigate the sensitivity of various parameters
when using the prEN 1591, and inventories have been made relating to the tightening of bolts,
whereby the reliability of the table from prEN 1591 is assessed, and relating to the developments
in the United States (PVRC) and Europe (EPERC).

One of the main characteristics of prEN 1591 is that it uses flange rotations in the flanged joint.
As long as the flanges calculated by means of this standard are large and heavy (rigid) and only
few flange rotations occur, prEN 1591 will not deviate greatly from the existing standards.
However, when the flanges are smaller and lighter, greater flange rotations will cause the new
standard to deviate more clearly. The mechanical engineering aspects of the underlying method
appear to be well-founded. This means that the flanged joint can be properly optimised from a
mechanical engineering perspective, provided all flange and gland data are fully known. At
present this is certainly not the case. As a result, predictions of leak-tightness based on prEN 1591
are not really reliable.

As the flange calculation takes account of flange rotations, the flanges calculated by means of
prEN 1591 will in general be lighter. The drawbacks of the new calculation method are
particularly obvious with light and smaller flanges.

In the Netherlands a joint industry project on the functioning of metal flange connections has
been undertaken under auspices of the Netherlands Institute of Welding (NIL) and co-ordinated
by the Project Office for Materials and Production Technology (PMP).

This report is concerned with the project task directed to the issue of controlling fugitive
emissions of metal flange connections.

EPERC Bulletin Nr 3 3
The estimated amount of fugitive emission is 22-27% of the total emission of volatile organic
substances in the Netherlands. The part related to flange connections amounts about 3% of the
total emission whereas 9% is related to fittings.
Until several years ago a limited number of companies performed emission measurements mainly
because of employee health legislation (so-called Arbo-wet). More and more measurements are
being used for quantifying total emissions.

The following recommendations have been made to arrive at a general strategy to control fugitive
emissions of flange connections.

1. In order to control fugitive emissions measures should not only be directed to flange
connections but they should include all types of fittings.
2. The methodology of EPA-21 "stratified" is considered appropriate for determination and the
control of emissions (at least recommended to start with). In this methodology standard
(fixed) emissions factors are used.
The effectiveness can be increased stepwise to a advanced refined analysis by:
- a measurement spread in time of the total installation
- a link with data from maintenance
- the use of actual measured emission data.
A further improvement can be achieved by the "Leak Rate Correlation" method making use
of more accurate and component specific data especially in the range of low emissions.
3. Companies do acknowledge the interest to establish a uniform (nationally or Europeanwide
accepted) measurement methodology. Additionally a uniform policy of the licensing
authorities is considered important.
4. A study aimed at the usefulness of data basis including data regarding emissions and the
effect of controlling measures is recommended.
5. The level of Quality Control with respect to mounting activities should be increased both via
mounting procedures and certification of personnel.

Within the framework of the NIL-project "Performance of metal flanged joints" KEMA
Nederland BV, in co-operation with DSM, Eriks, Gore and Klinger-Picoff, has studied the
selection procedure of gaskets. It is the aim of this study to collect present selection criterions and
methods, and use them as the ground for a common selection scheme.

Flanged joints are a source of constant emissions because of the permeability of gaskets to liquid
and gaseous media and because of transport of media between flange and gasket. About ten
percent of these emissions occur as a result of a wrong gasket. Both for environmental and for
safety aspects, it is important to select the right gasket.

Leak tightness classes formulated by PVRC and DIN 28090 e.g., are recommended as a base for
a universal coupling of media and leak-tightness classes. The design of flanges can also benefit
from such a classification of media via prEN 1591 which is still being developed. Further, it is
recommended that for all gaskets leak rates are determined as a function of applied pressure. A
start has been made in a BriteEuram project that was finished last year, but more gasket data (e.g.
Kammprofile and spiral wound gaskets) are highly needed. Eventually, the coupling between leak
tightness classes and media should be the basis for the total control of (leakage from) flanged
joints.


EPERC Bulletin Nr 3 4
In this report a gasket selection procedure is proposed in which the division of media in groups is
the central item. A coupling between those groups and a leak-tightness criterion offers the
opportunity to connect the gasket selection to the leak-tightness requirement of the flanged joint.
Present methods do not use a leakage criterion. Yet, little gasket material data are available and
emission limits have only been set for a limited amount of media. Therefore, at present, the
selection scheme can only guarantee maximum safety with respect to blow out of the gaskets and
large leak rates, rather then guarantee a specified emission.