Flange & Gasket Design: Dr.S.Raja, Associate Professor (Senior Grade), Dept of Chemical Engg, MIT

Flange & Gasket Design
Dr.S.Raja, Associate Professor (Senior

Grade), Dept of Chemical Engg, MIT
flange on a gas pipeline

Flanges for vessels….
Flange dimensions
= OD of the flange
= Bolt Circle Dia
= OD of the gasket
= Mean dia of the gasket

ID of the gasket =

Design of flanges
• It involves:
• Type of flange (Flange facing )

• Flange thickness
• Selection of gasket (type, material and
dimensions)
• Bolting

Types of flanges
• For design purposes, flanged facings are classified
as:
• Full-faced or Wide-faced flanges
– The gasket is applied all over the width of the flange.
– The bolt load required to tighten the joint is very high
and more number of bolts are needed……costly!!!
• Narrow faced flanges
– The gasket is applied inside the bolt circle.
– All the face contact area lies inside the circle enclosed by
the bolt holes
– Less number of bolts…..Cheap
Types of non-standard flanges
• For design purposes, flanged facings are
classified as:
• Full-faced or Wide-faced flanges
• The gasket is applied all over the width of the flange.
• The bolt load required to tighten the joint is very high and
more number of bolts are needed……costly!!!
• Narrow faced flanges
• The gasket is applied inside the bolt circle.
• All the face contact area lies inside the circle enclosed by
the bolt holes
• Better leak proof joint, since gasket in between two
flanges can be Dr.S.Raja,
pressed properly.
Associate Professor (Senior
• Full-faced flanges, Figure 13.34a: where the
face contact area extends outside the circle of
bolts; over the full face of the flange.
• Narrow-faced flanges, Figure 13.34b, c, d:

where the face contact area is located within
the circle of bolts.

Figure 13.34. Flange types and faces (a) Full-face flange.
Narrow-face: (Gasket within bolt circle
Dr.S.Raja, ) (b)Professor
Associate Flat face
(Senior(c) Raised face (d) Tongue and
groove (e) Ring type joint
Types of narrow-faced flanges
a) Plain or flat face
b) Raised face
c) Male and Female
d) Tongue and groove
e) Ring type

• Plain or flat face
– Mating faces of both flanges are flat
– Simple construction

• Raised face
– Same as flat face
– Better compression load on gasket as there is no
contact between metal faces at the point of load
application

• Male and female
– One face is raised and other is recessed
– Suitable for high press operation
– Blow out of gasket is prevented

• Tongue and groove
– Suitable for all types of pressure vessel
• Ring type
– Has got groove on both faces
– Special type of gaskets are needed

Gaskets
• Gaskets are used to make a leak-tight joint between
two surfaces.
• The purpose of the gasket is to provide a shield and
thereby avoid the leakage of process fluid form the
equipment.
• Any leakage of process fluid can cause hazard, fire,
damage to the process plant and even loss of life.
• Gasket is necessary in the flange joint because flanged

faces cant be tightened without gasket.

• Even though the flanged face is carefully machined, there can
be irregularities on them which may not be observed with
naked eyes.
• If such faces are tightened without gasket, there is always a

possibility of cracking of the faces
• When the gasket is placed on the flange face and the joints
are tightened by bolts, the gasket gets compressed and then
permanently deformed and seals the irregularities of the
flange faces and thus provides a leak-proof joint.
• In order to maintain this seal, sufficient load must be applied

to the connection to oppose the hydrostatic end force created
by the internal pressure of the system.

• It is impractical to machine flanges to the degree of
surface finish that would be required to make a
satisfactory seal under pressure without a gasket.
• Gaskets are made from “semi-plastic” materials;

which will deform and flow under load to fill the
surface irregularities between the flange faces, yet
retain sufficient elasticity to take up the changes in
the flange alignment that occur under load.

2 terminologies in gasket!!!
• 1.Gasket seating stress (y): its defined as the force
that has to be applied to the gasket to cause the
gasket to flow and seal the irregularities in the
flange faces per unit area.
• 2.Gasket factor (m): its defined as the ratio of the

min seating stress on the gasket required to
maintain a seal under operating conditions to the
internal pressure in the vessel.
Types of gasket
• A great variety of proprietary gasket materials is used, and
reference should be made to the manufacturers’ catalogues
and technical manuals when selecting gaskets for a particular
application.
• Design data for some of the more commonly used gasket

materials are given in Table 13.4.
• Further data can be found in the pressure vessel codes and

standards and in various handbooks; Perry et al. (1997).

Gasket selection
• The following factors must be considered when
selecting a gasket material:
• 1. The type of flange and flange face (full face or

narrow face)
• 2. The process conditions: pressure, temperature,
corrosive nature of the process fluid.
• 3. Whether repeated assembly and disassembly of the
joint is required.

• Up to pressures of 20 bar, the operating temperature and
corrosiveness of the process fluid will be the controlling factor
in gasket selection.
• Vegetable fibre and synthetic rubber gaskets can be used at

temperatures of up to 100°C.
• Solid polyfluorocarbon (Teflon) and compressed asbestos

gaskets can be used to a maximum temperature of about
260°C.
• Metal-reinforced gaskets can be used up to around 450°C.
• Plain soft metal gaskets are normally used for higher

temperatures. Grade), Dept of Chemical Engg, MIT
Gasket width ….(N)
• It is an important parameter which depends on flange facing and the
bolt load requirement.
• Go& Gi = Outside and inside dia of gasket respectively.
• actual gasket width, N is given by (Go– Gi)/2 and the ratio (Go/Gi )is
given by,
𝐺0 𝑦−𝑚𝑃 0.5
• =
𝐺𝑖 𝑦−𝑃(𝑚+1)
• Based on the above equation an appropriate size of the gasket

suitable for the requisite flange facing may be chosen.
• For initial iteration…..assume Gi = OD of shell + 5 mm extra????
• But….gaskets having different values of the seating stress and gasket

factor may be tried to arrive at a suitable width (N), to satisfy the
operating conditions!!!! Dr.S.Raja, Associate Professor (Senior
Location of gasket load reaction force (HG)

Few terms…..
• N = actual width of gasket • H = Hydrostatic end force =
• b0 = Basic gasket seating width (π/4)G2P
(before applying load) = N/2 • HP = total joint contact surface
• b = Effective gasket seating compression = π(2b)GmP
width (after applying load)
– b = b0, when b0 < 6.3mm • G = dia at location of gasket load
– b = ½ √b0, when b0 > 6.3mm reaction
• Bolt load due to initial gasket = mean dia of gasket contact face if
load reaction, Wm1 = πbGy b0 < 6.3mm
• HG = Gasket load reaction force = (Inside dia of gasket) + 2N – 2b if
= difference bet flange design b0 > 6.3mm
bolt load and total hydrostatic
end force = Wm2 – H = HP • hG = radial distance from gasket
• Wm2 = HP + H load reaction to the bolt circle =
(B
Dr.S.Raja, Associate Professor – G)/2
(Senior
• In the design of flanges two conditions are
important for bolt load calculations:
– Bolting – up condition (atmospheric condition)
– Operating condition

• Bolting-up conditions:
– 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 pressure and temperature.
– Bolt load due to initial gasket load reaction,

Wm1 = πbGy

• Operating conditions:
– 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, at the design
temperature & pressure.
– Under operating conditions, hydrostatic end force from the

internal design pressure tends to open the joint.
– Therefore, the bolt load at operating conditions,

Wm2 = H + HP = (π/4)G2P + π(2b)GmP

Min. Bolt area
• The min required bolt area shall be adequate to
provide the greater of the bolt loads (Wm1 or Wm2)
• This area is calculated by using the bolt stresses at the

temperatures appropriate to the two conditions
• i.e., Am1 = (Wm1 /fa) and Am2 = (Wm2 /fb)
• fa & fb = allowable stress values at atmospheric and

operating conditions respectively

Actual bolt area
• Ab = Actual bolt area, which will not be less than Am1 or Am2
to satisfy the theoretical requirement, should be chosen
from the standards.
• For this, standard size bolts should be chosen, sufficient to

give the required area.
• We can use either large no. of small bolts or small no. of

large bolts.
• The bolt size should not normally be less than 12 mm, as

smaller sizes can be sheared off by over-tightening.

Std. bolt size as per IS standards
Bolt OD/ID (mm) Area (mm2)
M – 18 17.1/16.5 {π/4(di2+do2)} /2 = 221.565
M – 20 19.1/18.5 277.5
M – 22 21/20.5 340
M – 24 23/22.5 394

• The larger area of the above Am1 or Am2 is chosen to calculate the
no. of bolts.
• No. of bolts = (Am1 or Am2)/(Bolt area)
• No. of bolts should be in the multiple of 4 ( say if no. bolts is

calculated as 10.05….choose the 12 as the final no. of bolts!!!!!)
• Therefore, Actual area, Ab = (Bolt area)(no. of bolts)

• …………so Ab will be > Am1 or Am2
• U have to use only this Ab for all other calculations!!!!

Bolt spacing
• It is the distance of the centers of two adjacent
bolts
• A large bolt spacing would cause a deflection of

the flange.
• If this deflection is excessive, the joint will leak.
• From stds…..the bolt spacing should be betwn

3.5 to 5 times of bolt dia.
Nmin
• Once the actual bolt area Ab is selected a check can be
made to determine the required min gasket width,
• Nmin = (Ab fa ) /2πyG
• If the selected gasket width, N > Nmin …….then design is

okay….
• Or the entire procedure should be repeated with a

suitable gasket width.

Bolt circle dia
• It should be consistent with the gasket dia and
the bolt spacing.
• B = BCD = OD of gasket + 2(bolt dia) + 12mm

Flange thickness
𝑃 0.5
• 𝑡𝑓 = 𝐺
𝐾𝑓
1
• Where 𝐾 = 1.5(𝑊𝑚 )(ℎ𝐺 )
0.3+
(𝐻)(𝐺)

Flange OD
• A = OD of the flange = BCD + (2xbolt size)

Flange/Gasket Design….Summary

Prob 1
• A vessel is designed for an internal pressure 100
kgf/cm2. A spiral wound metal, fibre stainless steel
gasket with inside diameter 36 cm and width 2.0 cm is
used.
• Gasket factor is 3.0, while gasket seating stress is 675
kgf/cm2. Permissible stress for bolt material at
atmospheric and operating condition is 1300 kgf/cm2.
• Check whether the gasket width is sufficient to keep it

away from crushing out?
Prob 2
• A pressure vessel has inside diameter 1470 mm and a plate thickness
of 5mm. Inside diameter of flange is 1482 mm. A gasket is provided
over the flange face. Gasket factor is 2.0 and the gasket seating stress
is 120 kgf/cm2.
• Inside diameter of gasket is 1485 mm. Pressure inside the vessel is 2.5
kgf/cm2.
• Permissible stress of flange material is 1060 kgf/cm2.
• Permissible stress in bolts under atmospheric condition is 600 kgf/cm2.
• Permissible stress in bolts at operating conditions is 550 kgf/cm2.
• Diameter of bolt is 20 mm.
• Calculate:
• i) Check whether the gasket width is sufficient to keep it away from
crushing out?
• ii) flange thickness
Prob 3
A narrow face flange is to be designed to the following specifications:
• Outside-diameter of shell = 80 cm; shell thickness = 10 mm
• Design pressure = 10 kgf/cm2.
• Design temperature = 150ºC.
• Gasket is of asbestos composition.
• Inside diameter of gasket = 84 cm.
• Gasket width = 1.6 cm.
• Gasket factor m = 2.75.
• Gasket seating stress = 260 kg/cm2.
• Permissible stress for the bolt material = 950 kg/cm2.
• Permissible stress for the flange material = 950 kg/cm2.
• 32 bolts of 19 mm diameter are to be used to tighten the flange joint.
• Check whether the gasket is sufficiently wide to keep away from
crushing.
• Calculate the minimum thickness of flange.
Prob 4: For the external pressure
problem….(based on Design problem 2)
• Gasket selection….since we’ve chosen the temperature as 250°C…as per
the guidelines…Up to pressures of 20 bar, the operating temperature and
corrosiveness of the process fluid will be the controlling factor in gasket
selection.
• So, From Table 4.1 (code book)….select….Corrugated metal, asbestos, soft

steel……
• m = 3 and y = 31 N/mm2
• @Design temp 250°C…..the bolt material, f = 16 kgf/mm2 = 1.57x108 N/m2
• …..the flange material, f = 12.1 kgf/mm2 = 1.19x108 N/m2
• Already we’ve found out that….. Di = 4175 mm
• Thickness, t = 40 mm
• Do = 4175+(2x40) = 4255 mm
• Internal pressure, P = (1.1) 150x103 N/m2 = 1.65x105 N/m2

Flange & Gasket Design: Dr.S.Raja, Associate Professor (Senior Grade), Dept of Chemical Engg, MIT

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Flange & Gasket Design

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

= Bolt Circle Dia

= Mean dia of the gasket

Dr.S.Raja, Associate Professor (Senior

• Type of flange (Flange facing )

Dr.S.Raja, Associate Professor (Senior

• Narrow-faced flanges, Figure 13.34b, c, d:

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

• Gasket is necessary in the flange joint because flanged

Dr.S.Raja, Associate Professor (Senior

• If such faces are tightened without gasket, there is always a

• In order to maintain this seal, sufficient load must be applied

Dr.S.Raja, Associate Professor (Senior

• Gaskets are made from “semi-plastic” materials;

Dr.S.Raja, Associate Professor (Senior

• 2.Gasket factor (m): its defined as the ratio of the

• Design data for some of the more commonly used gasket

• Further data can be found in the pressure vessel codes and

Dr.S.Raja, Associate Professor (Senior

• 1. The type of flange and flange face (full face or

Dr.S.Raja, Associate Professor (Senior

• Vegetable fibre and synthetic rubber gaskets can be used at

• Solid polyfluorocarbon (Teflon) and compressed asbestos

• Metal-reinforced gaskets can be used up to around 450°C.

• Plain soft metal gaskets are normally used for higher

• Based on the above equation an appropriate size of the gasket

• But….gaskets having different values of the seating stress and gasket

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

– Bolt load due to initial gasket load reaction,

Dr.S.Raja, Associate Professor (Senior

– Conditions required to resist the hydrostatic end force of

– Under operating conditions, hydrostatic end force from the

– Therefore, the bolt load at operating conditions,

Dr.S.Raja, Associate Professor (Senior

• This area is calculated by using the bolt stresses at the

• i.e., Am1 = (Wm1 /fa) and Am2 = (Wm2 /fb)

• fa & fb = allowable stress values at atmospheric and

Dr.S.Raja, Associate Professor (Senior

• For this, standard size bolts should be chosen, sufficient to

• We can use either large no. of small bolts or small no. of

• The bolt size should not normally be less than 12 mm, as

Dr.S.Raja, Associate Professor (Senior

Dr.S.Raja, Associate Professor (Senior

• No. of bolts = (Am1 or Am2)/(Bolt area)

• No. of bolts should be in the multiple of 4 ( say if no. bolts is

• Therefore, Actual area, Ab = (Bolt area)(no. of bolts)

• U have to use only this Ab for all other calculations!!!!

Dr.S.Raja, Associate Professor (Senior

• A large bolt spacing would cause a deflection of

• If this deflection is excessive, the joint will leak.

• From stds…..the bolt spacing should be betwn

• Nmin = (Ab fa ) /2πyG

• If the selected gasket width, N > Nmin …….then design is

• Or the entire procedure should be repeated with a

Dr.S.Raja, Associate Professor (Senior