Przemyslaw Lutkiewicz - Academia.edu (original) (raw)
Uploads
Papers by Przemyslaw Lutkiewicz
Volume 3: Fluid-Structure Interaction; High Pressure Technology
There are many International and National standards for flanges and clamp connections. Different ... more There are many International and National standards for flanges and clamp connections. Different bolt pretension values are required by these standards. In general, two bolt tightening methods are recognized: by torque or tension tools. The tensioning method is more accurate; however, this requires temporary higher pretension. ISO-27509, for example will need temporary bolt pretension equivalent to 90–95% of yield strength, API 6A allows up to 83% of bolt yield strength. Metric and Imperial bolting types can be used. Both types have related thread standards with specific tolerance classes. It is known from field experience that in some cases combination of thread tolerances, bolt size, and tightening with tension tool, the induced interference between the nut and stud threads can prevent the turning of the nut preventing the correct pre-load. This paper investigates the problem and proposes some solutions to avoid jamming. Paper will present general overview and deep problem investi...
Volume 3: Fluid-Structure Interaction; High Pressure Technology
To use bolted flange connection is a common way to connect the piping system components in oil an... more To use bolted flange connection is a common way to connect the piping system components in oil and power industry. In most of the cases the functionality, strength and tightness are assured by a proper flange type and material selection, followed by the existing design rules and hand calculation or FEA (Design by Analysis). In most cases the time dependent material properties are not considered, as the high temperature effects are minor. In this paper the author will focus on the high temperature applications, where time dependent material and flange properties need to be addressed. Shown on the Compact Flange example the design process and challenges related with high temperature conditions will be discussed. The definition of the critical temperature will be defined based on material creep properties. Design techniques used to predict long term connection behavior including bolt relaxation, flange material creep, loss of tightness and functionality within component lifetime will b...
Volume 3: Fluid-Structure Interaction; High Pressure Technology
In today’s environment, the functionality of a sealing solution is highly valued. The ability to ... more In today’s environment, the functionality of a sealing solution is highly valued. The ability to provide a solution with high sealing integrity and low fugitive emissions follows the industry trend for developing a more environmentally friendly solution. There are some existing standards and methodologies that provide a basis for practical testing activities. Other methodologies, such as FEA and hand calculations, are available to evaluate the seal tightness on a theoretical basis during the design stage and predict fugitive emissions values. Test measurement for fugitive emissions is subject to the design of the flange and seal components, the quality of those components, and the test set-up methods employed. This paper will focus on the comparison of different flange designs currently available in the market, as well as a comparison of various metal to metal seal types. The scope of this paper covers flanges designed to ASME B16.5, API 6A, non-standard flanges (e.g. compact flange...
Volume 1: Codes and Standards, 2019
There are currently no industry accepted methods for calculating sealing effectiveness of flange ... more There are currently no industry accepted methods for calculating sealing effectiveness of flange connections at the research and development phase of a project. As there are many different designs of bolted piping connectors being widely used in the oil and gas industry, operators and regulators could benefit greatly from a more accurate comparison and estimate of expected flange tightness level, based on design calculations only. This paper will propose a new methodology for sealing effectiveness estimation of bolted connections based on leak rate calculations. The methodology will combine practical simplicity and advance theory to get a simple but effective engineering/designing tool to assess the seal tightness. A new proposed method will be based on the contact stress pattern (FEA results), material properties (code specification) and surface finish/roughness (manufacture requirements) as inputs and leak rate estimation as an output. The Representative Surface Element concept wi...
The API flange design is a well-known commonly used solution. The flange concept was developed in... more The API flange design is a well-known commonly used solution. The flange concept was developed in late 1920s and 1930s by Waters and Taylor. The design methodology of the flange was published in 1937[1], well known as the “Taylor Forge method”. This is still the basis of the present ASME flange calculation. The design is based on the simple elastic principles and linear stress analysis/calculations. The conventional flange type dimensions are described in API 6A [2] and analyzed in API 6AF [3] and 6AF2 [4]. On the other hand, the Compact Flange concept was presented first by Webjørn in 1989 VCF joint [5]. It is based on plastic theory equations and plastic collapse capacity. In 1989 the initial concept was adopted by the Steel Product Offshore (SPO) company for oil industry by equipping flange with HX seal ring for raiser and subsea use. After that a topside budget version (with simpler IX seal ring) was prepared by SPO and presented on PVP 2002 conference [6][7][8]. The Compact Sta...
There are currently no industry accepted methods for calculating sealing effectiveness of flange ... more There are currently no industry accepted methods for calculating sealing effectiveness of flange connections at the research and development phase of a project. As there are many different designs of bolted piping connectors being widely used in the oil and gas industry, operators and regulators could benefit greatly from a more accurate comparison and estimate of expected flange tightness level, based on design calculations only. This paper will propose a new methodology for sealing effectiveness estimation of bolted connections based on leak rate calculations. The methodology will combine practical simplicity and advance theory to get a simple but effective engineering/designing tool to assess the seal tightness. A new proposed method will be based on the contact stress pattern (FEA results), material properties (code specification) and surface finish/roughness (manufacture requirements) as inputs and leak rate estimation as an output. The Representative Surface Element concept wi...
Volume 3: Fluid Structure Interaction; High Pressure Technology
Hydrogen Induced Stress Cracking (HISC) is a phenomena related with metals, with potentially seve... more Hydrogen Induced Stress Cracking (HISC) is a phenomena related with metals, with potentially severe consequences when utilizing Duplex / Super Duplex stainless steels in subsea equipment exposed to Cathodic Protection (CP). In general, the three conditions need to be present: hydrogen source (CP), susceptible material (Duplex/Super Duplex stainless steel) and high stresses/strains. The third one can be related with loads, calculation promises and parts design in general (for example risers). The designing rules to minimize the risk of HISC failure are still in development and the latest state of art is presented in DNVGL-RP-F112 June 2018 edition. The Compact Flange (CF) is much lighter and more robust connection than standard ASME or API types as the CF design methodology is based on plastic capacity which is presented in the ISO-27509 code. However, ISO standardization covers only topside applications (with IX seal ring type), pressure class range up to CL2500 and simplified face ...
Volume 3: Fluid Structure Interaction; High Pressure Technology
High-pressure applications such as process piping, pressure vessels, risers, pipelines, and subse... more High-pressure applications such as process piping, pressure vessels, risers, pipelines, and subsea production systems use bolted flange connections. Design of flanged joints may be done by design by rules and design by analysis. This paper presents a design by rules method applicable for flanges designed for face-to-face make-up. Limit loads are used to calculate the structural capacity (resistance) of the flanges, bolts, and metallic seal rings. Designers can use the calculation method to size bolted flange connections and calculate the structural capacity of existing bolted flange connections. Finite element analyses have been performed to verify the analytically based calculation method. The intention is to prepare for an ASME code case based on the calculation method presented in this paper.
Volume 3: Fluid Structure Interaction; High Pressure Technology
Latest development in oil and gas industry is focused on higher pressure and temperature. In addi... more Latest development in oil and gas industry is focused on higher pressure and temperature. In addition, standard oil and gas components are more frequent adapted to the other applications like aerospace, food processing, renewable energy. For those conditions, tightness is even more critical than before. In the existing codes the requirements for different tightness classes can be find as well as detailed fugitive emission test descriptions. However, the complete design methodology for HPHT seal solution is still missing. There is no engineering procedure/methodology in the code which will link the design concept, R&D process to the prototype and real tests results. The method which will predict tightness for each size and each configuration/condition is not there. Therefore, there is an urgent need to understand the leakage phenomena and describe it by simplified and safe engineering method. Method, which will connect the design concept with real behavior and be in agreement (or con...
International Journal of Pressure Vessels and Piping, 2010
Journal of Vacuum Science & Technology A, 2008
Volume 3: Fluid-Structure Interaction; High Pressure Technology
There are many International and National standards for flanges and clamp connections. Different ... more There are many International and National standards for flanges and clamp connections. Different bolt pretension values are required by these standards. In general, two bolt tightening methods are recognized: by torque or tension tools. The tensioning method is more accurate; however, this requires temporary higher pretension. ISO-27509, for example will need temporary bolt pretension equivalent to 90–95% of yield strength, API 6A allows up to 83% of bolt yield strength. Metric and Imperial bolting types can be used. Both types have related thread standards with specific tolerance classes. It is known from field experience that in some cases combination of thread tolerances, bolt size, and tightening with tension tool, the induced interference between the nut and stud threads can prevent the turning of the nut preventing the correct pre-load. This paper investigates the problem and proposes some solutions to avoid jamming. Paper will present general overview and deep problem investi...
Volume 3: Fluid-Structure Interaction; High Pressure Technology
To use bolted flange connection is a common way to connect the piping system components in oil an... more To use bolted flange connection is a common way to connect the piping system components in oil and power industry. In most of the cases the functionality, strength and tightness are assured by a proper flange type and material selection, followed by the existing design rules and hand calculation or FEA (Design by Analysis). In most cases the time dependent material properties are not considered, as the high temperature effects are minor. In this paper the author will focus on the high temperature applications, where time dependent material and flange properties need to be addressed. Shown on the Compact Flange example the design process and challenges related with high temperature conditions will be discussed. The definition of the critical temperature will be defined based on material creep properties. Design techniques used to predict long term connection behavior including bolt relaxation, flange material creep, loss of tightness and functionality within component lifetime will b...
Volume 3: Fluid-Structure Interaction; High Pressure Technology
In today’s environment, the functionality of a sealing solution is highly valued. The ability to ... more In today’s environment, the functionality of a sealing solution is highly valued. The ability to provide a solution with high sealing integrity and low fugitive emissions follows the industry trend for developing a more environmentally friendly solution. There are some existing standards and methodologies that provide a basis for practical testing activities. Other methodologies, such as FEA and hand calculations, are available to evaluate the seal tightness on a theoretical basis during the design stage and predict fugitive emissions values. Test measurement for fugitive emissions is subject to the design of the flange and seal components, the quality of those components, and the test set-up methods employed. This paper will focus on the comparison of different flange designs currently available in the market, as well as a comparison of various metal to metal seal types. The scope of this paper covers flanges designed to ASME B16.5, API 6A, non-standard flanges (e.g. compact flange...
Volume 1: Codes and Standards, 2019
There are currently no industry accepted methods for calculating sealing effectiveness of flange ... more There are currently no industry accepted methods for calculating sealing effectiveness of flange connections at the research and development phase of a project. As there are many different designs of bolted piping connectors being widely used in the oil and gas industry, operators and regulators could benefit greatly from a more accurate comparison and estimate of expected flange tightness level, based on design calculations only. This paper will propose a new methodology for sealing effectiveness estimation of bolted connections based on leak rate calculations. The methodology will combine practical simplicity and advance theory to get a simple but effective engineering/designing tool to assess the seal tightness. A new proposed method will be based on the contact stress pattern (FEA results), material properties (code specification) and surface finish/roughness (manufacture requirements) as inputs and leak rate estimation as an output. The Representative Surface Element concept wi...
The API flange design is a well-known commonly used solution. The flange concept was developed in... more The API flange design is a well-known commonly used solution. The flange concept was developed in late 1920s and 1930s by Waters and Taylor. The design methodology of the flange was published in 1937[1], well known as the “Taylor Forge method”. This is still the basis of the present ASME flange calculation. The design is based on the simple elastic principles and linear stress analysis/calculations. The conventional flange type dimensions are described in API 6A [2] and analyzed in API 6AF [3] and 6AF2 [4]. On the other hand, the Compact Flange concept was presented first by Webjørn in 1989 VCF joint [5]. It is based on plastic theory equations and plastic collapse capacity. In 1989 the initial concept was adopted by the Steel Product Offshore (SPO) company for oil industry by equipping flange with HX seal ring for raiser and subsea use. After that a topside budget version (with simpler IX seal ring) was prepared by SPO and presented on PVP 2002 conference [6][7][8]. The Compact Sta...
There are currently no industry accepted methods for calculating sealing effectiveness of flange ... more There are currently no industry accepted methods for calculating sealing effectiveness of flange connections at the research and development phase of a project. As there are many different designs of bolted piping connectors being widely used in the oil and gas industry, operators and regulators could benefit greatly from a more accurate comparison and estimate of expected flange tightness level, based on design calculations only. This paper will propose a new methodology for sealing effectiveness estimation of bolted connections based on leak rate calculations. The methodology will combine practical simplicity and advance theory to get a simple but effective engineering/designing tool to assess the seal tightness. A new proposed method will be based on the contact stress pattern (FEA results), material properties (code specification) and surface finish/roughness (manufacture requirements) as inputs and leak rate estimation as an output. The Representative Surface Element concept wi...
Volume 3: Fluid Structure Interaction; High Pressure Technology
Hydrogen Induced Stress Cracking (HISC) is a phenomena related with metals, with potentially seve... more Hydrogen Induced Stress Cracking (HISC) is a phenomena related with metals, with potentially severe consequences when utilizing Duplex / Super Duplex stainless steels in subsea equipment exposed to Cathodic Protection (CP). In general, the three conditions need to be present: hydrogen source (CP), susceptible material (Duplex/Super Duplex stainless steel) and high stresses/strains. The third one can be related with loads, calculation promises and parts design in general (for example risers). The designing rules to minimize the risk of HISC failure are still in development and the latest state of art is presented in DNVGL-RP-F112 June 2018 edition. The Compact Flange (CF) is much lighter and more robust connection than standard ASME or API types as the CF design methodology is based on plastic capacity which is presented in the ISO-27509 code. However, ISO standardization covers only topside applications (with IX seal ring type), pressure class range up to CL2500 and simplified face ...
Volume 3: Fluid Structure Interaction; High Pressure Technology
High-pressure applications such as process piping, pressure vessels, risers, pipelines, and subse... more High-pressure applications such as process piping, pressure vessels, risers, pipelines, and subsea production systems use bolted flange connections. Design of flanged joints may be done by design by rules and design by analysis. This paper presents a design by rules method applicable for flanges designed for face-to-face make-up. Limit loads are used to calculate the structural capacity (resistance) of the flanges, bolts, and metallic seal rings. Designers can use the calculation method to size bolted flange connections and calculate the structural capacity of existing bolted flange connections. Finite element analyses have been performed to verify the analytically based calculation method. The intention is to prepare for an ASME code case based on the calculation method presented in this paper.
Volume 3: Fluid Structure Interaction; High Pressure Technology
Latest development in oil and gas industry is focused on higher pressure and temperature. In addi... more Latest development in oil and gas industry is focused on higher pressure and temperature. In addition, standard oil and gas components are more frequent adapted to the other applications like aerospace, food processing, renewable energy. For those conditions, tightness is even more critical than before. In the existing codes the requirements for different tightness classes can be find as well as detailed fugitive emission test descriptions. However, the complete design methodology for HPHT seal solution is still missing. There is no engineering procedure/methodology in the code which will link the design concept, R&D process to the prototype and real tests results. The method which will predict tightness for each size and each configuration/condition is not there. Therefore, there is an urgent need to understand the leakage phenomena and describe it by simplified and safe engineering method. Method, which will connect the design concept with real behavior and be in agreement (or con...
International Journal of Pressure Vessels and Piping, 2010
Journal of Vacuum Science & Technology A, 2008