GD Engineering Reference Number: C-502077-1

Retford Road, Worksop, Nottinghamshire, England. S80 2PY. Page 1 of 18

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MIRKO
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2005.0
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27 +
04'00'

Description Bandlock Closure Calculations - ASME VIII

Client
Client’s Purchase Order No
GD Works Order No
Closure Basic Description
Assembly Drawing No
Tectubi S.p.A.
90/4029
502077
36 Inch Nominal Size Bandlock 2 Closure,
Band Size 20x67, Large Section Seal
1277-2516/502077

Rev Date Description Pages Originator Checked

0 1/10/04 First Issue 18 MSA

Originator: M.S. Atherton

Checked:

Date:

We have checked S31803 material designation and it is

correct. We confirm that stress value of 177.1 is
correct. The wall thickness has been calculated.
GD Engineering Reference Number: C-502077-1
Page 2 of 18

Foreword

Design Methodology

The closure functional design conforms to ASME VIII Div 1 Para UG 35(b) (1&2) in that :-

(1) The closure is so designed that “The closure and its holding elements are fully engaged in their intended
operating position before pressure can be built up in the vessel.”

(2) “Pressure tending to force the closure clear of the vessel will be released before the closure can be
fully opened for access.”

The Bandlock 2 quick acting closure utilises pressure loaded components which fall outside the rules provided
for “Standard” components as specified in ASME VIII Div 1.
With reference to ASME VIII Div 1 Para U-2(g) calculations have been performed on the three pressure
loaded parts i.e. Neck, Door and Band (Ref : G.A Dwg Part Nos. 1, 2 & 3) using stress categorisation
techniques specified in ASME VIII Div 2 Appendix 4 - “Design by Analysis”. Cyclic Fatigue analysis is
performed in accordance with ASME VIII Div 2 Appendix 5 - “Design Based on Fatigue Analysis”. Utilisation of
these techniques provides solutions as safe as those provided by Div 1 rules.

Closure neck wall thickness and hydrostatic test pressure are calculated using ASME B31.8 and ASME VIII
Div 1 UG 99 respectively.

Locking Band

Operational and mechanical strength requirements necessitate the selection of a specific grade of steel for this
component. Duplex steel conforming to ASME II SA479 UNS S31803 (flat bar) has proved successful in
meeting the loading and operational requirements of the locking band.

The attachment weld between locking band and operating lug does not constitute a critical loaded weld since
its failure would not in any way affect the safe load carrying capacity of the band.
GD Engineering Reference Number: C-502077-1
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CONTENTS

1. GENERAL 4

1.1 Introduction 4

1.2 Notation 4

1.3 Design Parameters 4

1.4 Material Properties 4

2. CALCULATIONS 5

2.1 Dimensional Data 5

2.2 Neck Wall Thickness Calculation to ASME B31.8 5

2.3 Minimum Hydrotest Calculation to ASME VIII Div 1 (UG99) 5

2.4 Hoop Stress Check at Test (Cold and New) for Closure Neck 5

3. ‘BEACON’ CALCULATIONS TO ASME VIII DIVISION 2 6

3.1 Method 6

3.2 Design Dimensions 7

3.3 Calculations 8

3.4 Results 8
3.4.1 Node Maps 9
3.4.2 Stresses around the Band 10
3.4.3 Stresses across Band Section A-A 11
3.4.4 Stresses around the Door 12
3.4.5 Stresses across Door Section A- A 13
3.4.6 Stresses across Door Section B-B 14
3.4.7 Stresses around the Neck 15
3.4.8 Stresses across Neck Section A-A 16
3.4.9 Stresses across Neck Section B-B 17

4. CONCLUSIONS 18
GD Engineering Reference Number: C-502077-1
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1. General

1.1 Introduction
The report details the calculations to demonstrate that the loaded components in a 36 inch nominal size
Bandlock 2 closure satisfies the necessary stress requirements for ASME VIII Divisions 1 and 2.

1.2 Notation
ASME VIII notation will be used throughout this report. A summary of the notation used in this report is given
below.

S1, S2, S3, S4 Stress categories ⎫

Pm Primary membrane stress intensity ⎪
Pb ⎪
Primary bending stress intensity ⎪
Q Secondary membrane plus bending stress intensity ⎪
F Peak stress intensity ⎬ ASME VIII Div2 Appendix 4
⎪
S Maximum allowable stress ⎪
Sa Fatigue stress intensity (ASME VIII Division 2 Appendix 5) ⎪
⎪
Sm Static design stress level ⎭
P Internal design pressure
Ph(calc) Calculated hydrostatic test pressure
Ph(actual) Actual hydrostatic test pressure
Tmax / Tmin Maximum / minimum design temperature
CA Corrosion allowance
σy & S Yield stress
σh Hoop stress at test
σd Design stress allowed from code
t Minimum wall thickness (ASME B31.8)
D Pipe wall outside diameter
F Design factor = 0.6
E Joint factor = 1 (ASME B31.8 Table 841.115A)
T Temperature factor = 1 (ASME B31.8 Table 841.116A)

1.3 Design Parameters

Design pressure 11.3 N/mm2
Working Pressure (max.) 11.3 N/mm²
Hydrostatic test pressure 15.82 N/mm²
Design temperature -29 to 85 °C
Corrosion allowance 3 mm
Cyclic requirements Not specified : 2000 cycles used

1.4 Material Properties

Door : Allowable stress values taken from ASME II Part D Appendix 1
Material ASTM A694 F60 (Hot tested at +85oC)
Yield @ +85oC = 415 N/mm2 Min. UTS @ +85oC = 515 N/mm2 Min.

Design stress 147.1 N/mm2 @ 85 °C

Neck : Allowable stress values taken from ASME II Part D Appendix 1

Material ASTM A694 F60 (Hot tested at +85oC)
Yield stress at ambient 415 N/mm²
Design stress (as per Door) 147.1 N/mm2 @ 85 °C

Band : Allowable stress values taken from ASME II Part D Table 1A

Material ASME II SA479 UNS S31803
Design stress 177.1 N/mm2 @ 85°C
GD Engineering Reference Number: C-502077-1
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2. Calculations

2.1 Dimensional Data

Closure bore 864.4 mm
Closure wall thickness 25 mm

NECK

MIN W/T

CLOSURE
BORE

2.2 Neck Wall Thickness Calculation to ASME B31.8 Factor 0.6

t = [(P x D) ÷ (2 x S x F x E x T)] + CA
t = [( 11.3 x 914.4 ) ÷ ( 2 x 413 x 0.6 x 1 x 1 )] + 3
t = 23.85 mm

Actual wall thickness used is 25mm. Wall thickness therefore meets the code requirements.

2.3 Minimum Hydrotest Calculation to ASME VIII Div 1 (UG99)

Ph(calc) = 1.3 x P
Ph(calc) = 1.3 x 11.3
Ph(calc) = 14.69 N/mm2
The actual hydrotest pressure used will be 15.82 N/mm2. The hydrotest pressure therefore meets the code
requirements.

2.4 Hoop Stress Check at Test (Cold and New) for Closure Neck
σh = [( D x Ph(actual) ) ÷ ( 2 x t x σy )] x 100%
σh = [( 914.4 x 15.82 ) ÷ ( 2 x 25 x 415 )] x 100%
σh = 69.72% of specified material yield
GD Engineering Reference Number: C-502077-1
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3. ‘BEACON’ Calculations to ASME VIII Division 2

3.1 Method
In addition to ASME B31.8 and ASME VIII Division 1 code assessment, the 36 inch Bandlock 2 closure, design
pressure 11.3 N/mm2, has been assessed to ASME VIII Division 2 - ‘Alternative rules for pressure vessels’.
The stresses used in the assessment were derived using the Boundary Element Technique. The software
used is based on the BEACON boundary element code written by Dr A.A.Becker author of ‘The Boundary
Element Method in Engineering’ published McGraw Hill 1992. The boundary element code was developed for
GD Engineering by the Component Design and Integrity (CDI) group, Department of Mechanical Engineering
at the University of Nottingham, UK. The software used is NT v2.1 (July 1998).
The boundary element representation of the closure is based on an automatically generated mesh of
axisymmetric Gaussian integration point elements. The mesh is refined in areas of stress concentration and
full solution convergence checks have been performed for a range of geometries. Stresses identified using
this technique are categorised and assessed in accordance with Appendix 4, with cyclic fatigue analysis
performed in accordance with Appendix 5.
The Boundary Element program has been verified by comparison with finite element analysis results
performed on six closure geometries and also with experimental results from electrical resistance strain gauge
testing of a full size closure.
GD Engineering Reference Number: C-502077-1
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3.2 Design Dimensions

The dimensions of the 36 inch Bandlock 2 closure used in the boundary element analysis can be seen below.

D1* D2 D4 D5 R1 R2 R3 R5 T1 T2 T3*
870.4 966 850 879.5 17 15 8 15 93.75 125 172.8

T4* T5γ T6 L1 L2 L3 L4γ L5 L6 L8 L9*

22 - 13.5 54.8 104.1 135 - 80 70 120 145

γ Applicable only for closures up to 24” Nominal Diameter and Class 600 or below.
* Dimensions shown for bore, wall thickness and centre door thickness are shown in the corroded condition.
GD Engineering Reference Number: C-502077-1
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3.3 Calculations
The following calculations are derived from ASME VIII Division 2 Appendix 4 -’Design based on stress
analysis’ and ASME VIII Division 2 Appendix 5 - ‘Design based on Fatigue analysis’.
ASME VIII Division 2 Section 4-110 states that the stress intensities calculated in the loaded components at
the design pressure shall not exceed the limits listed below.

S1 = Pm ≤ Sm N/mm2
S2= Pm+ Pb ≤ 1.5 Sm N/mm2
S3= Pm+ Pb+ Q ≤ 3.0 Sm N/mm2
S4= Pm+ Pb+ Q+ F (Fatigue) ≤ 2.0 Sa N/mm2

The table below summarises the maximum stress intensities allowed in the individual components. The fatigue
stress intensity (Sa) is obtained from graphs in ASME VIII Division 2, Appendix 5 based upon 2000 cycles.

Maximum Allowable Stress Intensities from ASME VIII Division 1

Neck Door Band

S1 = 147.1 N/mm2 S1 = 147.1 N/mm2 S1 = 177.1 N/mm2
S2 = 220.65 N/mm2 S2 = 220.65 N/mm2 S2 = 265.65 N/mm2
S3 = 441.3 N/mm2 S3 = 441.3N/mm2 S3 = 531.3 N/mm2
S4 = 884 N/mm2 S4 = 884 N/mm2 S4 = 840 N/mm2

3.4 Results
Using the dimensions on page 7, a boundary element analysis was carried out on the closure. Please refer to
the above section detailing the design parameters for the code requirements. The stress intensity results from
the boundary element program are summarised in the table below.

Maximum Stress Intensities Calculated from Boundary Element Analysis

Neck Door Band

S1 = 63.1 N/mm2 S1 = 63.5 N/mm2 S1 = 132.9 N/mm2
S2 = 143.9 N/mm2 S2 = 144.6 N/mm2 S2 = 156.3 N/mm2
S3 = 290.9 N/mm2 S3 = 186 N/mm2 S3 = 373.5 N/mm2
S4 = 290.9 N/mm2 S4 = 186 N/mm2 S4 = 373.5 N/mm2

The diagrams on the following page show the positions of the peripheral nodes and sections used in the
Boundary Element program. The sections have been placed across the areas of maximum stress, ascertained
from finite element analysis.
The diagrams on page 9 should be referred to when examining the stress distribution graphs.
GD Engineering Reference Number: C-502077-1
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3.4.1 Node Maps

GD Engineering Reference Number: C-502077-1
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3.4.2 Stresses around the Band

Fig. 1: Stress distribution on band surface: calc. ref.C-502077-1:

400

300

200 sint

100

stress MPa smax

0
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38

-100
smin

-200

-300 shoop

-400
node number
GD Engineering Reference Number: C-502077-1
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3.4.3 Stresses across Band Section A-A

Fig. 2: Stress distribution on band section A-A: calc. ref.C-502077-1:

200

150

100 sint

50

stress MPa smax

0
2 4 6 8 10 12

-50
smin

-100

-150 shoop

-200
node number
GD Engineering Reference Number: C-502077-1
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3.4.4 Stresses around the Door

Fig. 3: Stress distribution on door surface: calc. ref.C-502077-1:

200

150

100 sint

50

stress MPa smax

0
20 40 60 80 100 120 140 160

-50
smin

-100

-150 shoop

-200
node number
GD Engineering Reference Number: C-502077-1
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3.4.5 Stresses across Door Section A-A

Fig. 4: Stress distribution on door section A-A: calc. ref.C-502077-1:

150

100

sint
50

0
stress MPa 2 4 6 8 10 12 smax

-50

smin
-100

-150
shoop

-200
node number
GD Engineering Reference Number: C-502077-1
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3.4.6 Stresses across Door Section B-B

Fig. 5: Stress distribution on door section B-B: calc. ref.C-502077-1:

150

100

sint

50

stress MPa smax

0
2 4 6 8 10 12
smin

-50

shoop

-100
node number
GD Engineering Reference Number: C-502077-1
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3.4.7 Stresses around the Neck

Fig. 6: Stress distribution on neck surface: calc. ref.C-502077-1:

300

250

200

sint
150

100

stress MPa smax

50

0
20 40 60 80 100 120 140 160 180 200 220 240
smin
-50

-100

shoop
-150

-200
node number
GD Engineering Reference Number: C-502077-1
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3.4.8 Stresses across Neck Section A-A

Fig. 7: Stress distribution on neck section A-A: calc. ref.C-502077-1:

300

250

200 sint

150

stress MPa smax

100

50
smin

0
2 4 6 8 10 12

-50 shoop

-100
node number
GD Engineering Reference Number: C-502077-1
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3.4.9 Stresses across Neck Section B-B

Fig. 8: Stress distribution on neck section B-B: calc. ref.C-502077-1:

300

250

sint
200

150
stress MPa smax

100

smin
50

0
2 4 6 8 10 12 shoop

-50
node number
GD Engineering Reference Number: C-502077-1
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4. Conclusions
The calculations contained within this report show that the 36 inch nominal size Bandlock 2 closure, design
pressure 11.3 N/mm2, satisfies the requirements of ASME VIII Divisions 1 and 2 with the exception of Wall
thickness only meets requirements of ASME B31.8 Factor 0.6